Nanoporous membrane support in electrolytic cell

Abstract

The electrolytic cell comprises a first half-cell with a first electrode, a second half-cell with a second electrode, a separator separating the first half-cell from the second half-cell, where a compressive load is applied between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator, and a nanoporous support structure located between the first electrode and the separator, the nanoporous support structure being 100 micrometers thick or less.

Description

[Background technology]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 63 / 267,694, filed February 8, 2022, and entitled “NANOPROUS MEMBRANE SUPPORT IN AN ELECTROLYZER CELL,” the disclosure of which is incorporated by reference herein in its entirety.

[0002] (background) Hydrogen production can play a key role because hydrogen gas is required for many chemical processes. As of 2019, approximately 70 million tons of hydrogen are produced annually worldwide for a variety of uses, such as in oil refining, in the production of ammonia (through the Haber process), in the production of methanol (through the reduction of carbon monoxide), or as a fuel in transportation.

[0003] Historically, the majority of hydrogen (about 95%) has been produced from fossil fuels (e.g., by steam reforming of natural gas, partial oxidation of methane, or coal gasification). Other methods of hydrogen production include biomass gasification, low or no CO2 emission methane pyrolysis, and water electrolysis. Electrolysis uses electricity to split water molecules into hydrogen gas and oxygen gas. To date, electrolysis systems and methods have generally been more expensive than fossil fuel-based production methods. However, fossil fuel-based methods can be more environmentally damaging and generally result in increased CO2 emissions. Thus, there is a need for cost-competitive and environmentally friendly hydrogen gas production electrolysis systems and methods. Summary of the Invention [Means for solving the problem]

[0004] (summary) The present disclosure describes an electrolyzer cell comprising a first half-cell with a first electrode, a second half-cell with a second electrode, a separator separating the first half-cell from the second half-cell, where a compressive load is applied between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator, and a first nanoporous support structure located between the first electrode and the separator.

[0005] The present disclosure also describes a method of manufacturing an electrolyzer cell, the method including providing or receiving a first electrode, a second electrode, and a separator, positioning a first nanoporous support structure between the first electrode and the separator, positioning the second electrode relative to the separator, and applying a compressive load between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator. [Brief description of the drawings]

[0006] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0007] [Figure 1] FIG. 1 is a schematic diagram of an exemplary electrolyzer cell for the electrolysis of water to produce hydrogen gas that includes a nanoporous support structure that supports or protects a separator from mechanical forces imparted by one or both electrodes due to a compressive load imposed on one or both electrodes in the electrolyzer cell. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] (Detailed Description) The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of example, specific embodiments in which the present invention may be practiced. These embodiments, also referred to herein as "examples", are described in sufficient detail to enable those skilled in the art to practice the present invention. The exemplary embodiments may be combined, other embodiments may be utilized, or structural and logical changes may be made without departing from the scope of the present invention. While the disclosed subject matter will be described in conjunction with the enumerated claims, it should be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter. The following detailed description is therefore not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

[0009] References herein to "one embodiment," "an embodiment," "an example embodiment," and the like indicate that the embodiment being described may include a particular feature, structure, or characteristic, but that not all embodiments necessarily include that particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described in connection with one embodiment, it is provided that this is within the knowledge of one of ordinary skill in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0010] Values ​​expressed in range format should be interpreted in a flexible manner to include not only the numerical values ​​explicitly recited as limits of that range, but also all individual numerical values ​​or subranges contained within that range, as if each numerical value and subrange were explicitly recited. For example, a recited range of values ​​"from about 0.1 to about 5" should be interpreted to include not only the explicitly recited values ​​of about 0.1 and about 5, but also all individual concentrations within the recited range of values ​​(e.g., 1, 1.23, 2, 2.85, 3, 3.529, and 4) and subranges falling within the recited range (e.g., about 0.1% to 0.5%, about 1.21% to 2.36%, about 3.3% to 4.9%, or about 1.2% to 4.7%, to name just a few). The description "from about X to Y" has the same meaning as "from about X to about Y" unless otherwise indicated. Similarly, the statement "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z," unless otherwise indicated.

[0011] As used herein, the terms "a," "an," or "the" are used to include "one or more than one" unless the context clearly dictates otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise indicated. Unless otherwise indicated, the phrase "at least one of," when referring to a listed group, is used to mean any combination of one or more of the group members. For example, the statement "at least one of A, B, and C" can have the same meaning as "A, B, C, A and B, A and C, B and C, or A, B, and C," or the statement "at least one of D, E, F, and G" can have the same meaning as "D, E, F, G, D and E, D and F, D and G, E and F, E and G, F and G, D, E, and F, D, E, and G, D, F, and G, E, F, and G, or D, E, F, and G." Commas can be used to the left or right of the decimal symbol as a separator or digit grouping symbol, e.g., "0.000,1" is equivalent to "0.0001."

[0012] In the methods described herein, steps can be performed in any order without departing from the principles of the invention, except when a time or sequence of operations is explicitly recited. Furthermore, the steps defined can be performed in parallel unless express language recites them to be performed separately. For example, the recited act of doing X and the recited act of doing Y can be performed simultaneously in a single operation, and the resulting process would fall within the literal scope of the process. Recitation in a claim to the effect that a first step is performed, and then several other steps are subsequently performed, shall be taken to mean that the first step is performed before any of the other steps, but that the other steps may be performed in any suitable sequence, unless the sequence is further recited within the other steps. For example, a claim element reciting "step A, step B, step C, step D, and step E" shall be interpreted to mean that step A is performed first and step E is performed last, and that steps B, C, and D may be performed in any sequence between steps A and E (including one or more steps being performed in parallel with step A or step E) and the sequence still falls within the literal scope of the claimed process. A given step or subset of steps may also be repeated.

[0013] Moreover, recited steps can be performed in parallel unless express claim language recites them as being performed separately. For example, a claimed step of doing X and a claimed step of doing Y can be performed simultaneously in a single operation, and the resulting process would fall within the literal scope of the claimed process.

[0014] The term "about" as used herein can allow for a degree of variation within a value or range, e.g., within 10%, within 5%, within 1%, within 0.5%, within 0.1%, within 0.05%, within 0.01%, within 0.005%, or within 0.001% of a stated value, or within a stated limit of a range, inclusive of the exact value or range stated.

[0015] The term "substantially" as used herein refers to a "majority of" or "mostly," such as at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or greater, or 100%.

[0016] In addition, phraseology or terminology employed herein and not otherwise defined should be understood to be for purposes of description only and not for purposes of limitation. Furthermore, all publications, patents, and patent documents referred to herein are incorporated herein by reference in their entirety as if individually incorporated by reference. In the event of inconsistent usage between this document and those documents so incorporated by reference, the usage in the incorporated references should be considered to support that of this document, and in the event of irreconcilable inconsistencies, the usage in this document shall prevail.

[0017] Hydrogen gas (H2) can be formed electrochemically by a water splitting reaction in which water is split into oxygen gas (O2) and H2 gas at the anode and cathode of an electrochemical cell, respectively. Examples of such electrochemical processes include, but are not limited to, proton electrolyte membrane (PEM) electrolysis and alkaline water electrolysis (AWE). In such electrochemical reactions, the operating energy required to drive the water splitting electrolysis reaction is high due to additional energy costs as a result of various energy inefficiencies. For example, to reduce unwanted migration of ionic species between the electrodes, the cathode and anode may be separated by a separator, such as a membrane, which can reduce the migration of ionic species. Although the separator can improve the overall efficiency of the cell, this may come at the cost of additional resistive losses within the cell, which in turn increases the operating voltage. Other inefficiencies in water electrolysis may include solution resistive losses, electrical conduction inefficiencies, and / or electrode overpotentials, among others.

[0018] FIG. 1 is a schematic diagram of a typical water electrolyzer cell 100 that uses electrical power to electrolytically convert water (H2O) into hydrogen gas (H2) and oxygen gas (O2), as illustrated in FIG. 1. In one embodiment, the electrolyzer cell 100 comprises two half-cells, a first half-cell 111 and a second half-cell 121. In one embodiment, the first and second half-cells 111, 121 are separated by a separator 131, such as a membrane 131. In one embodiment, the separator 131 comprises a porous membrane (e.g., a microporous membrane or a nanoporous membrane), an ion exchange membrane, or an ion solvation membrane. In an embodiment where the separator 131 comprises an ion exchange membrane, the membrane can be of different types, such as an anion exchange membrane (AEM), a cation exchange membrane (CEM), a proton exchange membrane (PEM), or a bipolar ion exchange membrane (BEM).

[0019] In embodiments where the separator 131 is a cation exchange membrane, the cation exchange membrane can be a conventional membrane such as those available from Asahi Kasei Corp. (Tokyo, Japan), or from Membrane International Inc. (Glen Rock, NJ, USA), or from Chemours Company (Wilmington, DE, USA). Examples of cation exchange membranes include, but are not limited to, membranes sold by Chemours Company under the trade name N2030WX, and membranes sold by Asahi Kasei Corp. under the trade names F8020 / F8080 or F6801. Examples of materials that can be used to form the cation exchange membrane include, but are not limited to, perfluoropolymers containing anionic groups, such as sulfonic acid groups and / or carboxylic acid groups. However, it should be understood that in some embodiments, cation exchange membranes that are more restrictive and therefore restrict migration of one species of cation while allowing migration of another species of cation, depending on the need to restrict or allow migration of a particular cation or anionic species between electrolytes, can be used. Similarly, in some embodiments, depending on the need to restrict or allow migration of a particular anion species between electrolytes, anion exchange membranes may be used that are more restrictive, thus allowing migration of one species of anion while restricting migration of another species of anion. Such restrictive cation and anion exchange membranes are commercially available and can be selected by one of skill in the art.

[0020] In some embodiments, the separator 131 can be selected such that it can function in acidic and / or alkaline electrolyte solutions, as appropriate. Other properties for the separator 131 that may be desirable include, but are not limited to, high ionic selectivity, low ionic resistance, high burst strength, and high stability in electrolyte solutions within a temperature range of room temperature up to 150° C. or higher.

[0021] In one embodiment, the separator 131 is stable within a temperature range of about 0°C to about 150°C, e.g., about 0°C to about 100°C, about 0°C to about 90°C, etc., for example, about 0°C to about 80°C, about 0°C to about 70°C, etc., for example, about 0°C to about 60°C, about 0°C to about 50°C, etc., for example, about 0°C to about 40°C, or about 0°C to about 30°C, etc.

[0022] To achieve a desired product or products in the electrolyte solution, it may be useful to use ion-specific ion exchange membranes that allow migration of one type of ion (e.g., cations for CEMs and anions for AEMs) but not another, or one type of ion and another.

[0023] In one embodiment, the first half cell 111 includes a first electrode 112, which may be positioned proximate to the separator 131, and the second half cell 121 includes a second electrode 122, which may be positioned proximate to the separator 131, for example, on the opposite side of the separator 131 from the first electrode 112. In one embodiment, the first electrode 112 is an anode for the electrolyzer cell 100 and the second electrode 122 is a cathode for the electrolyzer cell 100, and thus, in the remainder of this disclosure, the first half cell 111 may also be referred to as the anode half cell 111, the first electrode 112 may also be referred to as the anode 112, the second half cell 121 may also be referred to as the cathode half cell 121, and the second electrode 122 may also be referred to as the cathode 122. Each of the electrodes 112, 122 can be coated with one or more electrocatalysts to accelerate the reaction towards hydrogen gas (H2 gas) and / or oxygen gas (O2 gas). Examples of electrocatalysts include, but are not limited to, highly dispersed metals or alloys of platinum group metals such as platinum, palladium, ruthenium, rhodium, iridium, or combinations thereof such as platinum-rhodium, platinum-ruthenium, nickel mesh coated with ruthenium oxide (RuO2), or high surface area nickel.

[0024] In one embodiment, the anode 112 is electrically connected to an external positive conductor 116 (also referred to as the "anode conductor 116") and the cathode 122 is electrically connected to an external negative conductor 126 (also referred to as the "cathode conductor 126"). When the separator 131 is wetted and in electrolytic contact with the electrodes 112 and 122 and an appropriate voltage is applied across the conductors 116 and 126, O2 gas is liberated at the anode 112 and H2 gas is liberated at the cathode 122. In one configuration, an electrolyte, for example, consisting of a solution of KOH in water, is pumped into the half cells 111, 121. For example, the electrolyte can flow into the anode half cell 111 through a first electrolyte inlet 114 and into the cathode half cell 121 through a second electrolyte inlet 124. In an embodiment, the flow of electrolyte through the anode half cell 111 traps the produced O2 gas as bubbles 113 that exit the anode half cell 111 through a first outlet 115. Similarly, the flow of electrolyte through the cathode half cell 121 can trap the produced H2 gas as bubbles 123 that can exit the cathode half cell 121 through a second outlet 125. Gas can be separated from the electrolyte downstream of the electrolyzer cell 100 using one or more suitable separators. In an embodiment, the produced H2 gas is dried and collected in a high pressure canister or pumped into further process elements. The O2 gas can simply be allowed to vent to the atmosphere or can be stored for other uses. In an embodiment, the electrolyte is recycled back into the half cells 111, 121 as needed.

[0025] In one embodiment, a typical voltage across the electrolyzer cell 100 (e.g., the voltage difference between the anode conductor 116 and the cathode conductor 126) is between about 1.5 volts (V) and about 3.0 V. In one embodiment, the operating current density for the electrolyzer cell 100 is about 0.1 A / cm 2 ~About 3A / cm 2Each cell 100 has a size large enough to produce very large quantities of H2 gas when operated at these current densities. In one embodiment, the cross-sectional area of ​​each cell 100 (e.g., width x height for a rectangular cell) is about 0.25 square meters (m 2 ) ~ approx. 15m 2 , about 1m 2 ~about 5m 2 For example, about 2 m 2 ~about 4m 2 , about 2.25m 2 ~about 3m 2 etc., approximately 2.5m 2 ~ approx. 2.9m 2 In one embodiment, the total volume (e.g., width x height x depth) of each cell is approximately 0.1 cubic meters (m 3 ) ~ approx. 2m 3 , about 0.15m 3 ~about 1.5m 3 etc., for example, about 0.2 m 3 ~ approx. 1m 3 , about 0.25m 3 ~about 0.5m 3 etc., for example, about 0.275 m 3 ~about 0.3m 3 In one embodiment, the total volume of the entire electrolyzer system (e.g., the combined volume of all cells in all stacks in a plant) is about 1 m 3 ~about 25,000m 3 , about 5m 3 ~about 2,500m 3 etc., for example, about 10m 3 ~ approx. 100m 3 , about 25m 3 ~about 75m 3 For example, about 30 m 3 ~About 50m 3 It is.

[0026] The ohmic resistance of the separator 131 can affect the voltage drop across the anode 112 and the cathode 122. For example, as the ohmic resistance of the separator 131 increases, the voltage across the anode 112 and the cathode 122 can increase, and vice versa. In some embodiments, the separator 131 has a relatively low ohmic resistance and a relatively high ionic mobility. In some embodiments, the separator 131 has a relatively high hydration characteristic that increases with temperature, thus decreasing the ohmic resistance. By selecting a separator 131 with a lower ohmic resistance, as known in the art, the voltage drop across the anode 112 and the cathode 122 at a specified temperature can be reduced.

[0027] The efficiency of the electrolyzer cell 100 may depend on the resistive losses between the anode 112 and the cathode 122. One parameter that may affect the ohmic resistance between the electrodes 112, 122 is the distance between the anode 112 and the cathode 122, with a larger gap between the electrodes 112, 122 resulting in a larger resistance compared to a correspondingly smaller gap. Thus, in an embodiment, the electrolyzer cell 100 may be configured such that the space or gap between the anode 112 and the cathode 122 is as small as possible. In one exemplary configuration, one or both of the anode 112 and the cathode 122 are positioned such that the electrodes 112, 122 are in contact with the separator 131, also referred to as a "zero gap" configuration. In an embodiment of the zero gap configuration, one face or surface of the anode 112 contacts a first surface of the separator 131 and one face or surface of the cathode 122 contacts an opposing second surface of the separator 131.

[0028] In some embodiments, the zero gap configuration can be accomplished by positioning an elastic element adjacent to one or both of the electrodes 112, 122. In some embodiments, the elastic element comprises a compressible and expandable structure that provides a controlled compressive load when compressed a defined amount. The overall structure of the anode 112, separator 131, cathode 122, and elastic element can be compressed, for example, between a support structure or housing of the electrolyzer cell 100, which generates a load that occurs as the elastic element attempts to expand back to its fully extended position, which acts to load the electrodes 112, 122 against the separator 131 and provide the zero gap configuration. In some embodiments, the elastic element comprises a corrugated mesh structure. In some embodiments, the elastic element comprises one or more conductive structures such that electrical current can flow through the elastic element and into or out of the electrodes 112, 122 over which the elastic element is compressed.

[0029] In one embodiment, the elastic element comprises one or more conductive filaments woven together in the elastic layer that expand and collapse when the elastic layer is compressed, applying a controlled compressive load. In some embodiments, the elastic element is a corrugated mesh having a preload of about 2 pounds per square inch when compressed to about 3 mm. In some embodiments, the uncompressed thickness of the elastic element is about 5 mm to about 7 mm. The elastic element can have a corrugation pitch of about 10 mm. In some embodiments, the elastic element is formed from a wire having a wire diameter of about 0.15 mm.

[0030] In the embodiment shown in FIG. 1 , the elastic element 140 is included only on the cathode side of the separator 131 such that a load force is applied only to the cathode 122 by the elastic element 140, compressing the cathode 122 into the separator 131. The load force applied by the elastic element 140 may be sufficient to generate a load force also between the separator 131 and the anode 112, for example by pushing the separator 131 into the anode 112. Those skilled in the art will appreciate that an elastic element may also be included on the anode side of the separator 131 in addition to or instead of the cathode side elastic element 140 shown in FIG. 1 . In the embodiment shown, the electrolyzer cell 100 includes a cell support 142 on the rear side of the elastic element 140, where the elastic element 140 is compressed between the cell support 142 and the cathode 122. The cell support 142 may be coupled to a housing or chassis of the electrolyzer cell 100. For example, the cell support 142 can be a current collector, and current can flow between the cell housing and the current collector 142 .

[0031] In one embodiment, a fluid pressure differential can be applied across the separator 131 (e.g., pressure on the cathode side of the separator 131 is greater than on the anode side, or vice versa). The pressure differential, in addition to the elastic element 140, can act to load the electrodes 112, 122 and create effective electrical contact across the active areas of the electrodes 112, 122, particularly for fine mesh electrodes.

[0032] As will be understood by one of ordinary skill in the art, one or both of the electrodes 112, 122 may include structures that, when the electrodes 112, 122 are loaded onto the separator 131, may result in mechanical wear and eventual damage to the separator 131. For example, one or both of the electrodes 112, 122 may include raised structures that, when loaded onto the separator 131, may protrude into the material of the separator 131 and over time may wear and damage the separator 131. One type of structure that may be used as one or both of the electrodes 112, 122 is a fine woven mesh that may comprise a network of a set of intersecting wires that may be perpendicular or angled relative to one another, alternating between crossing and bending over one another. For example, any particular wire may alternate between passing under an adjacent crossing wire and then over the next crossing wire. In one embodiment, one or both of electrodes 112, 122 can comprise a woven wire mesh electrode formed from wire having a wire diameter of about 0.18 mm with an opening in the mesh of about 0.44 mm and an open area of ​​about 50% to about 60%, such as about 50% to about 55%. In one embodiment, one or both of electrodes 112, 122 is formed from an expanded mesh, where one or both of electrodes 112, 122 is fabricated from a sheet of material that is about 0.13 mm thick with a long diamond shaped side (LWD) of about 2 mm and a short diamond shaped side (SWD) of about 1 mm.

[0033] Often, when a wire mesh structure is used as one or both of the electrodes 112, 122, the electrodes 112, 122 contact the separator 131 and an apex is formed where the wires of the woven mesh overlap another wire. Relatively high localized contact stresses can arise at the apex contact points between the woven mesh electrodes 112, 122 and the separator 131 if allowed to come into direct contact. In particular, separators 131 that are very thin, e.g., 100 micrometers (μm) or less, can be more easily punctured or otherwise damaged by load contact between the apex wires of the electrodes 112, 122 and the separator 131. Additionally, the loading force of the elastic element 140 and / or the pressure differential between the anode and cathode sides of the separator 131 can create stresses on the separator 131 that can cause portions of the separator 131 to stretch into open spaces of the electrodes 112, 122, such as the gaps between the wires in the woven mesh electrodes 112, 122. The stretched separator 131, in addition to wire tops or other raised electrode structures being compressed against the separator 131, can ultimately result in the creation of localized thin spots or perforations in the separator 131.

[0034] In certain embodiments, the electrolyzer cell 100 can include one or more separator support structures located between the anode 112 and the separator 131, between the cathode 122 and the separator 131, or both between the anode 112 and the separator 131 and the cathode 122 and the separator 131. The one or more separator support structures can be compressed between the separator 131 and the corresponding electrode 112, 122 and can act to provide mechanical protection for the separator 131 and to mitigate or minimize mechanical stress between the electrodes 112, 122 and the separator 131, as described above. In the embodiment shown in FIG. 1 , the electrolyzer cell 100 includes a first separator support structure 150 (also referred to as the “anode side support structure 150”) located between the anode 112 and the separator 131, and a second separator support structure 152 (also referred to as the “cathode side support structure 152”) located between the cathode 122 and the separator 131.

[0035] In certain embodiments, the one or more separator support structures 150, 152 can comprise one or more nanoporous support sheets positioned between the anode 112 and the separator 131, between the cathode 122 and the separator 131, or both between the anode 112 and the separator 131 and between the cathode 122 and the separator 131. For example, the anode-side support structure 150 can comprise an anode-side nanoporous support sheet 150 positioned between the anode 112 and the separator 131, and the cathode-side support structure 152 can comprise a cathode-side nanoporous support sheet 152 positioned between the cathode 122 and the separator 131.

[0036] Each nanoporous support sheet 150, 152 can comprise a porous body with pores, at least some of which extend throughout the body from one side to the opposing side of the nanoporous support sheet 150, 152. In some embodiments, the pores are configured such that an electrolyte solution can pass through the nanoporous support sheet 150, 152 such that there is an electrolyte pathway between the separator 131 and the electrodes 112, 122 from which the nanoporous support sheet 150, 152 protects the separator 131. In some embodiments, at least a portion of the surface of the nanoporous support sheet 150, 152 that will be exposed to the electrolyte solution is hydrophilic such that the surface of the nanoporous support sheet 150, 152 will be effectively wetted by the electrolyte solution as it flows through the electrolytic cell 100. If the surfaces of the nanoporous support sheets 150, 152 do not wet sufficiently, the electrolyte solution may not pass efficiently through the nanoporous support sheets 150, 152, which may result in increased resistance across the separator 131. Hydrophilic surfaces wet readily when contacted with an alkaline solution, such as an alkaline electrolyte solution (e.g., KOH), that may be used in the electrolyzer cell 100.

[0037] One or both of the nanoporous support sheets 150, 152 can be made from a hydrophilic material, which forms the main body of the nanoporous support sheet 150, 152. For example, the main body of the nanoporous support sheet 150, 152 can be made essentially from a hydrophilic polymer, such as polyethersulfone (PES). In some embodiments, the main body of the nanoporous support sheet 150, 152 can be made from a polymeric hybrid comprising both hydrophilic and hydrophobic polymers, or from a copolymer comprising both hydrophilic and hydrophobic polymer blocks. Including a hydrophobic component (either in the form of a polymeric hybrid including a hydrophobic polymer, or a copolymer with a hydrophobic block) can make the nanoporous support sheet 150, 152 easier to process, such as by lowering the phase transition temperature for the polymer forming the nanoporous support sheet 150, 152, and / or to enhance the mechanical properties of the nanoporous support sheet 150, 152. In other embodiments, the main body of the nanoporous support sheet 150, 152 can be made from a non-hydrophilic material, such as a hydrophobic polymer, that is surface treated to produce hydrophilicity on at least a portion of the surface of the nanoporous support sheet 150, 152. Surface treatments can also be applied to materials that are inherently hydrophilic. Examples of surface treatments that may be used on the nanoporous support sheet 150, 152 include, but are not limited to, plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), or application of a hydrophilic coating.

[0038] In some embodiments, the main body of one or both of the nanoporous support sheets 150, 152 comprises a polymeric material, such as a hydrophilic polymer, a hydrophobic polymer (which may be surface treated to provide hydrophilicity as described above), a polymer hybrid comprising both hydrophilic and hydrophobic polymers, or a copolymer comprising one or more hydrophilic blocks and one or more hydrophobic blocks. Examples of polymers that may be used to form one or both of the nanoporous support sheets 150, 152 include, but are not limited to, polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

[0039] As will be appreciated by those skilled in the art, significant volumes of gas are produced within the electrolyzer cell 100, for example, H2 gas at the cathode 122 and O2 gas at the anode 112. Ion exchange through the nanoporous support sheets 150, 152 and separator 131 may be impeded if the pores of the nanoporous support sheets 150, 152 fill and remain filled with this gas. Thus, in certain embodiments, one or both of the nanoporous support sheets 150, 152 are configured to avoid, minimize, or reduce permeation of gas through the nanoporous support sheets 150, 152. Gas permeation through the nanoporous support sheet 150, 152 has been found to be directly related to the hydrophilicity of the surface of the nanoporous support sheet 150, 152, the tortuosity of the pores in the nanoporous support sheet 150, 152, and the size of the pores in the nanoporous support sheet 150, 152. In particular, the inventors have found that pore size is particularly relevant, and that gas will not form or migrate into the pores for pore sizes that are about 100 nanometers (nm) or less. In one embodiment, the largest pore in one or both of the nanoporous support sheets 150, 152 has a size of about 100 nm or less, e.g., about 95 nm or less, 90 nm or less, etc., for example, about 85 nm or less, about 80 nm or less, etc., for example, about 75 nm or less, about 70 nm or less, etc., for example, about 65 nm or less, 60 nm or less, etc., for example, about 55 nm or less, about 50 nm or less, etc., for example, about 45 nm or less, about 40 nm or less, etc., for example, about 35 nm or less, 30 nm or less, etc., for example, about 25 nm or less, about 20 nm or less, etc., for example, about 15 nm or less, about 10 nm or less, etc.

[0040] When little or no gas is trapped within the pores of the nanoporous support sheets 150, 152, the nanoporous support sheets 150, 152 add very little overall resistance to the electrolyzer cell 100. For example, it has been found that when little or no gas is trapped within the pores of a 100 μm thick nanoporous support sheet 150, 152, the nanoporous support sheet 150, 152 introduces a resistance to the electrolyzer cell 100 comparable to a 100 μm gap between the electrodes 112, 122 and the separator 131, which is filled with an alkaline electrolyte solution. In one embodiment, the total thickness of the nanoporous support sheets 150, 152 is as thin as is practical to minimize the resistance added to the electrolyzer cell 100 by the inclusion of the nanoporous support sheets 150, 152. However, the nanoporous support sheets 150 , 152 should also be thick enough to provide the separator 131 with sufficient mechanical protection from mechanical stresses resulting from compressive loading between the electrodes 112 , 122 and the separator 131 .

[0041] In an embodiment, each nanoporous support sheet 150, 152 has a thickness of about 250 μm or less, such as about 240 μm or less, 230 μm or less, such as, for example, 225 μm or less, 220 μm or less, such as, for example, 210 μm or less, 200 μm or less, such as, for example, 195 μm or less, 190 μm or less, such as, for example, 185 μm or less, 180 μm or less, such as, for example, 175 μm or less, 170 μm or less, such as, for example, 165 μm or less, 160 μm or less, such as, for example, 155 μm or less, 150 μm or less, such as, for example, 145 μm or less, 140 μm or less, such as, for example, 135 μm or less, 130 μm or less, such as, for example, It has a thickness of 125 μm or less, such as 120 μm or less, for example 115 μm or less, 110 μm or less, such as 105 μm or less, 100 μm or less, for example 95 μm or less, 90 μm or less, such as 85 μm or less, 80 μm or less, for example 75 μm or less, 70 μm or less, such as 65 μm or less, 60 μm or less, for example 55 μm or less, 50 μm or less, such as 45 μm or less, 40 μm or less, for example 35 μm or less, 30 μm or less, such as 25 μm or less, 20 μm or less, for example 15 μm or less, 10 μm or less. In one embodiment, the thickness of the anode side nanoporous support sheet 150 is the same as the thickness of the cathode side nanoporous support sheet 152, e.g., when the total thickness of the nanoporous support sheets 150, 152 is about 200 μm, the thickness of the anode side nanoporous support sheet 150 is about 100 μm and the thickness of the cathode side nanoporous support sheet 152 is also about 100 μm.

[0042] In an embodiment, one or more of the nanoporous support sheets 150, 152 can be added to the electrolyzer cell 100 as individual sheets. For example, the anode-side nanoporous support sheet 150 can be placed over the anode 112, then the separator 131 can be placed over the anode-side nanoporous support sheet 150. The cathode-side nanoporous support sheet 152 can then be placed over the separator 131, and finally the cathode 122 can be placed over the cathode-side nanoporous support sheet 152. Alternatively, an integrated multi-layer structure can be fabricated, for example, by laminating the nanoporous support sheets 150, 152 onto one or both sides of the separator 131. The lamination of one or more of the nanoporous support sheets 150, 152 and the separator 131 can be implemented using any of several common processes, such as using a dynamic reel-to-reel process or a static process using a heated press.

[0043] (Example) Various embodiments of the invention may be better understood by reference to the following examples, which are provided by way of illustration and are not intended to limit the invention to the examples given herein.

[0044] A 120 μm thick sheet of polyethersulfone (PES) with 30 nm pores was tested in a laboratory-scale electrolytic cell. The resulting voltage polarization curve was 3 A / cm 2The cell voltage for two of the 120 μm thick PES sheets (e.g., a first 120 μm thick nanoporous PES sheet between the separator and the anode and a second 120 μm thick nanoporous PES sheet between the separator and the cathode) was about 800 mV higher than the same cell configuration without the nanoporous PES support sheet. It is expected that the voltage drop across the support sheet will be proportional to the thickness. The inventors believe that there are no technical barriers to producing substantially thinner nanoporous support sheets (e.g., as thin as 25 μm thick) at the size required for operation in a commercial electrolyzer cell. All other things being equal, if two 25 μm thick nanoporous support sheets are used, the total expected voltage increase would be approximately 170 mV over the voltage across an equivalent cell without the nanoporous support sheet. Separator life may be dramatically increased, potentially making the "cost" in increased voltage worthwhile. In practice, the optimal thickness of the nanoporous support sheet will balance the voltage cost against the increased mechanical robustness of the multi-layered structure (e.g., separator 131 and one or both of anode-side nanoporous support sheet 150 and cathode-side nanoporous support sheet 152) compared to operation without the nanoporous support sheet.

[0045] (Additional embodiments) Below are provided exemplary embodiments, the numbering of which should not be construed as designating a level of importance. To illustrate the systems and methods disclosed herein, a non-limiting list of exemplary embodiments is provided herein.

[0046] Embodiment 1 may include subject matter (such as an apparatus, device, method, or one or more means for performing an action), such as an electrolytic cell system comprising a first half-cell with a first electrode, a second half-cell with a second electrode, a separator separating the first half-cell from the second half-cell, where a compressive load is applied between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator, and a first nanoporous support structure located between the first electrode and the separator.

[0047] Embodiment 2 can include or optionally be combined with the subject matter of embodiment 1, optionally including a first nanoporous support structure configured to support or protect the separator from mechanical forces imposed between the separator and the first electrode due to compressive loading.

[0048] Embodiment 3 may include or may optionally be combined with the subject matter of one or a combination of embodiment 1 and embodiment 2, and optionally includes a first nanoporous support structure that is 200 micrometers thick or less.

[0049] Embodiment 4 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-3, optionally including a first nanoporous support structure that is 150 micrometers thick or less.

[0050] Embodiment 5 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-4, optionally including a first nanoporous support structure that is 125 micrometers thick or less.

[0051] Embodiment 6 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-5, optionally including a first nanoporous support structure that is 100 micrometers thick or less.

[0052] Embodiment 7 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-6, optionally including a first nanoporous support structure that is 50 micrometers thick or less.

[0053] Embodiment 8 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-7, optionally including a first nanoporous support structure that is 25 micrometers thick or less.

[0054] Embodiment 9 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-8, optionally including a pore size of the first nanoporous support structure that is 100 nanometers or less.

[0055] Embodiment 10 may include or optionally be combined with the subject matter of one or any combination of embodiments 1-9, optionally including a pore size of the first nanoporous support structure that is 75 nanometers or less.

[0056] Embodiment 11 can include or can optionally be combined with the subject matter of one or any combination of embodiments 1-10, optionally including a pore size of the first nanoporous support structure that is 50 nanometers or less.

[0057] Embodiment 12 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-11, optionally including a pore size of the first nanoporous support structure that is 30 nanometers or less.

[0058] Embodiment 13 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-12, optionally including a first nanoporous support structure comprising a polymeric material having pores formed therein.

[0059] Embodiment 14 can include or can optionally be combined with the subject matter of embodiment 13, optionally including a polymeric material comprising a hydrophilic polymer.

[0060] Embodiment 15 can include or can optionally be combined with the subject matter of embodiment 13, optionally including a polymeric material comprising a hydrophobic polymer.

[0061] Embodiment 16 can include, or can optionally be combined with, the subject matter of embodiment 13, optionally including a polymeric material comprising a blend of hydrophilic and hydrophobic polymers.

[0062] Embodiment 17 may comprise or may be optionally combined with the subject matter of one or any combination of embodiments 13-16, optionally comprising a polymeric material comprising a copolymer comprising a hydrophilic block and a hydrophobic block.

[0063] Embodiment 18 may include or may be optionally combined with the subject matter of one or any combination of embodiments 13-17, optionally including a polymeric material comprising at least one of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

[0064] Embodiment 19 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-18, and optionally includes at least a portion of the surface of the first nanoporous support structure being hydrophilic.

[0065] Embodiment 20 may include or may optionally be combined with the subject matter of one or any combination of embodiments 1-19, optionally including a first nanoporous support structure that is treated with a surface treatment to provide hydrophilicity.

[0066] Embodiment 21 can include or can optionally be combined with the subject matter of embodiment 20, optionally including a surface treatment including at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and application of a hydrophilic coating.

[0067] Embodiment 22 may include or may be optionally combined with the subject matter of one or any combination of embodiments 1-21, optionally including one or more first elastic elements configured to generate at least a portion of the compressive load.

[0068] Embodiment 23 may include or optionally be combined with the subject matter of embodiment 22, and optionally includes one or more first elastic elements positioned adjacent to the first electrode, wherein a portion of the compressive load generated by the one or more first elastic elements compresses the first electrode toward the separator.

[0069] Embodiment 24 may include or optionally be combined with the subject matter of embodiment 23, optionally including one or more second elastic elements configured to generate a second portion of the compressive load, the one or more second elastic elements being positioned adjacent to the second electrode, the second portion of the compressive load compressing the second electrode towards the separator.

[0070] Embodiment 25 may include or optionally be combined with the subject matter of embodiment 22, and optionally includes one or more first elastic elements positioned adjacent to the second electrode, wherein a portion of the compressive load generated by the one or more first elastic elements compresses the second electrode toward the separator.

[0071] Embodiment 26 may include or may be optionally combined with the subject matter of one or any combination of embodiments 1-25, optionally including a second nanoporous support structure located between the second electrode and the separator.

[0072] Embodiment 27 can include or optionally combine the subject matter of embodiment 26, and optionally includes a second nanoporous support structure configured to support or protect the separator from mechanical forces imposed between the second electrode and the separator due to compressive loading.

[0073] Embodiment 28 may include or may be optionally combined with the subject matter of one or a combination of embodiment 26 and embodiment 27, and optionally includes a second nanoporous support structure that is 200 micrometers thick or less.

[0074] Embodiment 29 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-28, optionally including a second nanoporous support structure that is 150 micrometers thick or less.

[0075] Embodiment 30 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-28, and optionally includes a second nanoporous support structure that is 125 micrometers thick or less.

[0076] Embodiment 31 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-30, and optionally includes a second nanoporous support structure that is 100 micrometers thick or less.

[0077] Embodiment 32 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-31, optionally including a second nanoporous support structure that is 50 micrometers thick or less.

[0078] Embodiment 33 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-32, optionally including a second nanoporous support structure that is 25 micrometers thick or less.

[0079] Embodiment 34 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-33, optionally including a pore size of the second nanoporous support structure that is 100 nanometers or less.

[0080] Embodiment 35 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-34, optionally including a pore size of the second nanoporous support structure that is 75 nanometers or less.

[0081] Embodiment 36 may include or optionally be combined with the subject matter of one or any combination of embodiments 26-35, optionally including a pore size of the second nanoporous support structure that is 50 nanometers or less.

[0082] Embodiment 37 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-36, optionally including a pore size of the second nanoporous support structure that is 30 nanometers or less.

[0083] Embodiment 38 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-37, optionally including a second nanoporous support structure comprising a polymeric material having pores formed therein.

[0084] Embodiment 39 can include or can optionally be combined with the subject matter of embodiment 38, optionally including a polymeric material of the second nanoporous support structure comprising a hydrophilic polymer.

[0085] Embodiment 40 can include or can optionally be combined with the subject matter of embodiment 38, optionally including a polymeric material of the second nanoporous support structure comprising a hydrophobic polymer.

[0086] Embodiment 41 can include or can optionally be combined with the subject matter of embodiment 38, optionally including a polymeric material of the second nanoporous support structure comprising a hybrid of a hydrophilic polymer and a hydrophobic polymer.

[0087] Embodiment 42 may include or may be optionally combined with the subject matter of one or any combination of embodiments 38-41, optionally including a polymeric material of the second nanoporous support structure comprising a copolymer comprising a hydrophilic block and a hydrophobic block.

[0088] Embodiment 43 may include or may be optionally combined with the subject matter of one or any combination of embodiments 38-42, optionally including a polymeric material of the second nanoporous support structure comprising at least one of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

[0089] Embodiment 44 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-43, and optionally includes at least a portion of the surface of the second nanoporous support structure being hydrophilic.

[0090] Embodiment 45 may include or may optionally be combined with the subject matter of one or any combination of embodiments 26-44, optionally including a second nanoporous support structure that is treated with a surface treatment to provide hydrophilicity.

[0091] Embodiment 46 may include or optionally combine with the subject matter of embodiment 45, optionally including surface treatment of the second nanoporous support structure including at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and application of a hydrophilic coating.

[0092] Embodiment 47 may include or be optionally combined with the subject matter of one or any combination of embodiments 1-46, and may include subject matter (such as an apparatus, device, method, or one or more means for performing an action), for example, a method of manufacturing an electrolytic cell, the method including the steps of providing or receiving a first electrode, a second electrode, and a separator, positioning a first nanoporous support structure between the first electrode and the separator, positioning the second electrode relative to the separator, and applying a compressive load between the separator and the first electrode, or between the separator and the second electrode, or between the first and second electrodes and the separator.

[0093] Embodiment 48 can include or can optionally be combined with the subject matter of embodiment 47, optionally including a first nanoporous support structure configured to support or protect the separator from mechanical forces imposed between the first electrode and the separator due to compressive loading.

[0094] Embodiment 49 may include or may optionally be combined with the subject matter of one or a combination of embodiment 47 and embodiment 48, and optionally includes a first nanoporous support structure that is 200 micrometers thick or less.

[0095] Embodiment 50 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-49, and optionally includes a first nanoporous support structure that is 150 micrometers thick or less.

[0096] Embodiment 51 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-50, and optionally includes a first nanoporous support structure that is 125 micrometers thick or less.

[0097] Embodiment 52 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-51, and optionally includes a first nanoporous support structure that is 100 micrometers thick or less.

[0098] Embodiment 53 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-52, optionally including a first nanoporous support structure that is 50 micrometers thick or less.

[0099] Embodiment 54 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-53, optionally including a first nanoporous support structure that is 25 micrometers thick or less.

[0100] Embodiment 55 may include or optionally be combined with the subject matter of one or any combination of embodiments 47-54, optionally including a pore size of the first nanoporous support structure that is 100 nanometers or less.

[0101] Embodiment 56 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-55, optionally including a pore size of the first nanoporous support structure that is 75 nanometers or less.

[0102] Embodiment 57 may include or optionally be combined with the subject matter of one or any combination of embodiments 47-56, optionally including a pore size of the first nanoporous support structure that is 50 nanometers or less.

[0103] Embodiment 58 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-57, optionally including a pore size of the first nanoporous support structure that is 30 nanometers or less.

[0104] Embodiment 59 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-58, optionally including surface treating the first nanoporous support structure to provide hydrophilicity.

[0105] Embodiment 60 may include or optionally combine with the subject matter of embodiment 59, optionally including surface treating including at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and applying a hydrophilic coating onto the first nanoporous support structure.

[0106] Embodiment 61 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-60, and optionally includes a first nanoporous support structure comprising a polymeric material having pores formed therein.

[0107] Embodiment 62 can include or can optionally be combined with the subject matter of embodiment 61, optionally including a polymeric material of the first nanoporous support structure comprising a hydrophilic polymer.

[0108] Embodiment 63 can include or can optionally be combined with the subject matter of embodiment 61, optionally including a polymeric material of the first nanoporous support structure comprising a hydrophobic polymer.

[0109] Embodiment 64 may include or optionally combine with the subject matter of embodiment 61, optionally including a polymeric material of the first nanoporous support structure comprising a hybrid of a hydrophilic polymer and a hydrophobic polymer.

[0110] Embodiment 65 may include or may be optionally combined with the subject matter of one or any combination of embodiments 61-64, and optionally includes a polymeric material of the first nanoporous support structure comprising a copolymer comprising a hydrophilic block and a hydrophobic block.

[0111] Embodiment 66 may include or may be optionally combined with the subject matter of one or any combination of embodiments 61-65, and optionally includes a polymeric material of the first nanoporous support structure comprising at least one of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

[0112] Embodiment 67 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-66, and optionally includes at least a portion of the surface of the first nanoporous support structure being hydrophilic.

[0113] Embodiment 68 may include or may be optionally combined with the subject matter of one or any combination of embodiments 47-67, and optionally includes positioning one or more first elastic elements adjacent to the first electrode, the one or more first elastic elements generating at least a portion of the compressive load, the portion of the compressive load generated by the one or more first elastic elements compressing the first electrode toward the separator.

[0114] Embodiment 69 may include or optionally be combined with the subject matter of embodiment 68, and optionally includes positioning one or more second elastic elements adjacent to the second electrode, the one or more second elastic elements generating at least a second portion of the compressive load, the second portion of the compressive load generated by the one or more second elastic elements compressing the second electrode toward the separator.

[0115] Embodiment 70 may include or may be optionally combined with the subject matter of one or any combination of embodiments 47-69, and optionally includes positioning one or more elastic elements adjacent to the second electrode, the one or more elastic elements generating at least a portion of the compressive load, the portion of the compressive load generated by the one or more elastic elements compressing the second electrode toward the separator.

[0116] Embodiment 71 may include or may optionally be combined with the subject matter of one or any combination of embodiments 47-70, optionally including positioning a second nanoporous support structure between the second electrode and the separator.

[0117] Embodiment 72 can include or can optionally be combined with the subject matter of embodiment 71, and optionally includes a second nanoporous support structure configured to support or protect the separator from mechanical forces applied between the second electrode and the separator due to compressive loading.

[0118] Embodiment 73 may include or may be optionally combined with the subject matter of one or any combination of embodiment 71 and embodiment 72, optionally including surface treating the second nanoporous support structure to provide hydrophilicity.

[0119] Embodiment 74 may include or optionally combine with the subject matter of embodiment 73, optionally including surface treating including at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and applying a hydrophilic coating onto the second nanoporous support structure.

[0120] Embodiment 75 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-74, and optionally includes a second nanoporous support structure that is 200 micrometers thick or less.

[0121] Embodiment 76 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-75, optionally including a second nanoporous support structure that is 150 micrometers thick or less.

[0122] Embodiment 77 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-76, and optionally includes a second nanoporous support structure that is 125 micrometers thick or less.

[0123] Embodiment 78 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-77, and optionally includes a second nanoporous support structure that is 100 micrometers thick or less.

[0124] Embodiment 79 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-78, optionally including a second nanoporous support structure that is 50 micrometers thick or less.

[0125] Embodiment 80 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-79, and optionally includes a second nanoporous support structure that is 25 micrometers thick or less.

[0126] Embodiment 81 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-80, optionally including a pore size of the second nanoporous support structure that is 100 nanometers or less.

[0127] Embodiment 82 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-81, optionally including a pore size of the second nanoporous support structure that is 75 nanometers or less.

[0128] Embodiment 83 may include or optionally be combined with the subject matter of one or any combination of embodiments 71-82, optionally including a pore size of the second nanoporous support structure that is 50 nanometers or less.

[0129] Embodiment 84 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-83, optionally including a pore size of the second nanoporous support structure that is 30 nanometers or less.

[0130] Embodiment 85 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-84, optionally including a second nanoporous support structure comprising a polymeric material having pores formed therein.

[0131] Embodiment 86 can include or can optionally be combined with the subject matter of embodiment 85, optionally including a polymeric material of the second nanoporous support structure comprising a hydrophilic polymer.

[0132] Embodiment 87 can include or can optionally be combined with the subject matter of embodiment 85, optionally including a polymeric material of the second nanoporous support structure comprising a hydrophobic polymer.

[0133] Embodiment 88 can include or can optionally be combined with the subject matter of embodiment 85, optionally including a polymeric material of the second nanoporous support structure comprising a hybrid of a hydrophilic polymer and a hydrophobic polymer.

[0134] Embodiment 89 may include or may be optionally combined with the subject matter of one or any combination of embodiments 85-88, optionally including a polymeric material of the second nanoporous support structure comprising a copolymer comprising a hydrophilic block and a hydrophobic block.

[0135] Embodiment 90 may include or may be optionally combined with the subject matter of one or any combination of embodiments 85-89, optionally including a polymeric material of the second nanoporous support structure comprising at least one of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

[0136] Embodiment 91 may include or may optionally be combined with the subject matter of one or any combination of embodiments 71-90, and optionally includes at least a portion of the surface of the second nanoporous support structure that is hydrophilic.

[0137] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are also referred to herein as "examples." Such examples may include elements in addition to those shown or described. However, the inventors also contemplate examples in which only those elements shown or described are provided. The inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof) or with respect to other examples (or one or more aspects thereof) shown or described herein.

[0138] In the event of a conflicting usage between this document and any document so incorporated by reference, the usage in this document shall control.

[0139] The terms "a" or "an" are used herein, as is common in patent documents, to include "one or more than one," independent of any other instance or usage of "at least one" or "one or more." The term "or" is used herein to refer to a non-exclusive "or," such that "A or B" includes "A but not B," "B but not A," and "A and B," unless otherwise indicated. The terms "including" and "in which" are used herein as the plain English equivalents of the respective terms "comprising" and "wherein." Also, in the following claims, the terms "including" and "comprising" are open-ended, i.e., systems, devices, articles, compositions, formulations, or processes that include elements in addition to those listed after such terms in a claim, are still considered to be within the scope of that claim. Also, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels and are not intended to impose numerical requirements on their purposes.

[0140] The method embodiments described herein can be at least partially machine or computer implemented. Some embodiments can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform the methods as described in the above embodiments. Such method implementations can include code, such as microcode, assembly language code, higher level language code, or the like. Such code can include computer-readable instructions for performing various methods. The code can form part of a computer program product. Furthermore, in some embodiments, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memory (RAM), read-only memory (ROM), and the like.

[0141] The above description is intended to be illustrative and not restrictive. For example, the above described embodiments (or one or more aspects thereof) may be used in combination with each other. Other embodiments may also be used by those skilled in the art upon review of the above description. The Abstract is provided to comply with 37 C.FR §1.72(b) to enable the reader to quickly ascertain the nature of the present technical disclosure. It should be considered with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above detailed description, various features may be grouped together to simplify the disclosure. This should not be construed as intending that an unclaimed disclosed feature is essential to any claim. Rather, the subject matter of the invention may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are incorporated herein as examples or embodiments into the detailed description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments may be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. 1. An electrolyser cell comprising: a first half cell with a first electrode; a second half cell with a second electrode; a separator separating the first half-cell from the second half-cell, wherein a compressive load is applied between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator; a first nanoporous support structure located between the first electrode and the separator; and 1. An electrolyzer cell comprising:

2. 10. The electrolyzer cell of claim 1, wherein the first nanoporous support structure is 100 micrometers thick or less.

3. 3. The electrolyzer cell of claim 1 or claim 2, wherein the pore size of the first nanoporous support structure is 100 nanometers or less.

4. 4. The electrolyzer cell of claim 1, wherein the first nanoporous support structure comprises a polymeric material having pores formed therein.

5. 5. The electrolyzer cell of claim 4, wherein the polymeric material comprises a hydrophilic polymer, a hydrophobic polymer, a hybrid of hydrophilic and hydrophobic polymers, or a copolymer comprising hydrophilic and hydrophobic blocks.

6. 6. The electrolyser cell of claim 4 or claim 5, wherein the polymeric material comprises at least one of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethersulfone (PES), polyphenylene sulfide (PPS), and polyphenylsulfone (PPSU).

7. 7. The electrolyzer cell of claim 1, wherein at least a portion of a surface of the first nanoporous support structure is hydrophilic.

8. 8. The electrolyzer cell of claim 1, further comprising a second nanoporous support structure located between the second electrode and the separator.

9. 9. The electrolyzer cell of claim 8, wherein the second nanoporous support structure is 100 micrometers thick or less.

10. 10. The electrolyser cell of claim 8 or claim 9, wherein the pore size of the second nanoporous support structure is 100 nanometers or less.

11. Electrolyzer cell according to any one of claims 1 to 10, further comprising a resilient element configured to generate at least a portion of the compressive load.

12. 1. A method of manufacturing an electrolyser cell, the method comprising: providing or receiving a first electrode, a second electrode, and a separator; Positioning a first nanoporous support structure between the first electrode and the separator; positioning the second electrode relative to the separator; applying a compressive load between the separator and the first electrode, or between the separator and the second electrode, or between both the first and second electrodes and the separator; A method comprising:

13. The method of claim 12 , wherein the first nanoporous support structure is no more than about 100 micrometers thick.

14. 14. The method of claim 12 or claim 13, wherein the pore size of the first nanoporous support structure is about 100 nanometers or less.

15. The method of any one of claims 12-14, further comprising surface treating the first nanoporous support structure to render it hydrophilic.

16. 16. The method of claim 15, wherein the surface treating comprises at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and applying a hydrophilic coating onto the first nanoporous support structure.

17. The method of any one of claims 12-16, further comprising positioning a second nanoporous support structure between the second electrode and the separator.

18. The method of claim 17 , wherein the second nanoporous support structure is no more than about 100 micrometers thick.

19. 19. The method of claim 17 or claim 18, wherein the pore size of the second nanoporous support structure is about 100 nanometers or less.

20. The method of any one of claims 17-19, further comprising surface treating the second nanoporous support structure to render it hydrophilic.

21. 21. The method of claim 20, wherein the surface treating comprises at least one of plasma exposure, ultraviolet light exposure, corona discharge, ion-assisted reaction (IAR), and application of a hydrophilic coating onto the second nanoporous support structure.

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