Provided herein are electrochemical cell and/or electrolyzer configurations with membrane-electrode gap and optionally one or more spacers; and methods to use and manufacture the same.

Provided herein are electrochemical cell and/or electrolyzer configurations with membrane-electrode gap and optionally one or more spacers; and methods to use and manufacture the same.

In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

In polymer electrolyte membrane (PEM) fuel cells and electrolyzes, attaining and maintaining high membrane conductivity and durability is crucial for performance and efficiency. The use of low equivalent weight (EW) perfluorinated ionomers is one of the few options available to improve membrane conductivity. However, excessive dimensional changes of low EW ionomers upon application of wet/dry or freeze/thaw cycles yield catastrophic losses in membrane integrity. Incorporation of ionomers within porous, dimensionally-stable perforated polymer electrolyte membrane substrates provides improved PEM performance and longevity. The present invention provides novel methods using micromolds to fabricate the perforated polymer electrolyte membrane substrates. These novel methods using micromolds create uniform and well-defined pore structures. In addition, these novel methods using micromolds described herein may be used in batch or continuous processing.

An electrochemical system and process are provided to convert an amount of chalcopyrite (CuFeS.sub.2) to a product including copper ions. In an electrochemical reactor, a potential is applied across an anode and a cathode to convert the chalcopyrite to an intermediate, chalcocite (Cu.sub.2S). The anode is covered to prevent contact with the intermediate, thus limiting subsequent conversion of the intermediate to covellite (CuS) in favor of conversion to a material more suited to chemical oxidation, cuprite (Cu.sub.2O). For example, the anode can be covered with one or more layers of filter paper. Upon application of an oxidizing agent, the cuprite is oxidized to produce a product including copper ions. The cathode and covered anode allow for efficient and inexpensive processing. The cost of this technique is comparable to industry standards, and moreover, has a much smaller environmental footprint than heat-based copper extraction.

An electrochemical system and process are provided to convert an amount of chalcopyrite (CuFeS.sub.2) to a product including copper ions. In an electrochemical reactor, a potential is applied across an anode and a cathode to convert the chalcopyrite to an intermediate, chalcocite (Cu.sub.2S). The anode is covered to prevent contact with the intermediate, thus limiting subsequent conversion of the intermediate to covellite (CuS) in favor of conversion to a material more suited to chemical oxidation, cuprite (Cu.sub.2O). For example, the anode can be covered with one or more layers of filter paper. Upon application of an oxidizing agent, the cuprite is oxidized to produce a product including copper ions. The cathode and covered anode allow for efficient and inexpensive processing. The cost of this technique is comparable to industry standards, and moreover, has a much smaller environmental footprint than heat-based copper extraction.

An alkaline water electrolyzer includes at least two outer frames, a gasket, and a diaphragm. The at least two outer frames are stacked so as to overlap at least in part in a circumferential direction. The gasket is sandwiched between the two outer frames. The gasket can be in contact with the outer frames over the entire circumferential direction. In an inner peripheral surface of the gasket, a slit is formed along the circumferential direction. The gasket has a first protrusion portion. The first protrusion portion protrudes over the entire circumferential direction at a position overlapping the slit when viewed from a thickness direction of the slit. A diaphragm is caught in the slit of the gasket. A volume ratio of volume of the first protrusion portion, to volume between a bottom of the slit and an end of the diaphragm, is between 0.5 and 100 inclusive.

An alkaline water electrolyzer includes at least two outer frames, a gasket, and a diaphragm. The at least two outer frames are stacked so as to overlap at least in part in a circumferential direction. The gasket is sandwiched between the two outer frames. The gasket can be in contact with the outer frames over the entire circumferential direction. In an inner peripheral surface of the gasket, a slit is formed along the circumferential direction. The gasket has a first protrusion portion. The first protrusion portion protrudes over the entire circumferential direction at a position overlapping the slit when viewed from a thickness direction of the slit. A diaphragm is caught in the slit of the gasket. A volume ratio of volume of the first protrusion portion, to volume between a bottom of the slit and an end of the diaphragm, is between 0.5 and 100 inclusive.

A platform technology that uses a novel membrane electrode assembly, including a cathode layer, an anode layer, a membrane layer arranged between the cathode layer and the anode layer, the membrane conductively connecting the cathode layer and the anode layer, in a CO.sub.x reduction reactor has been developed. The reactor can be used to synthesize a broad range of carbon-based compounds from carbon dioxide and other gases containing carbon.

Electrochemical device using thin micro-porous metal sheets. The porous metal sheet may have a thickness less than 200 μm, provides three-dimensional networked pore structures of pore sizes in the range of 2.0 nm to 5.0 μm, and is electrically conductive. The micro-porous metal sheet is used for positively and/or negatively-charged electrodes by providing large specific contact surface area of reactants/electron. Nano-sized catalyst or features can be added inside pores of the porous metal sheet of pore sizes at sub- and micrometer scale to enhance the reaction activity and capacity. Micro-porous ceramic materials may be coated on the porous metal sheet at a thickness of less than 40 μm to enhance the functionality of the porous metal sheet and may function as a membrane separator. The electrochemical device may be used for decomposing molecules and for synthesis of molecules such as synthesis of ammonia from water and nitrogen molecules.