This disclosure relates to polymer electrolyte membranes, and in particular, to a composite membrane having at least two reinforcing layers comprising a microporous polymer structure and a surprisingly high resistance to piercing. This disclosure also relates to composite membrane-assemblies and electrochemical devices comprising the composite membranes of the disclosure, and to methods of manufacture of the composite membranes.

Membrane assemblies and separation layer(s) for electrochemical devices such as fuel cells and/or electrolyzers are provided, as well as their production methods. The separation layer(s) include surface-charged particles such as LDH particles to strengthen the membranes, enhance their ionic conductivity and prevent or reduce membrane dehydration and/or chemical degradation. In various configurations a single or few, relatively thick separation layer(s) with surface-charged particles may be used, while in other configurations alternating layers of ionomeric material and layers with surface-charged particles may be used, optimizing ionic conductivity with mechanical strength. Thin protective layers with solids content up to 100% may be set adjacent to the electrodes, and the orientation of the surface-charged particles may be set to enhance the ion conductivity of the respective layer.

An ion exchange membrane containing: a layer S containing a fluorine-containing polymer having a sulfonic acid group; a layer C containing a fluorine-containing polymer having a carboxylic acid group; and—a plurality of reinforcing materials functioning as at least one of reinforcement yarn and sacrifice yarn; wherein, when the ion exchange membrane is viewed from a top surface, an average cross-sectional thickness A of the ion exchange membrane measured in pure water for a region, is μm or more and 75 μm or less, and wherein a strength change ratio calculated from strength S2 of the ion exchange membrane measured after the ion exchange membrane is subjected to a predetermined electrolysis test and strength S1 of the ion exchange membrane measured before the ion exchange membrane is subjected to the electrolysis test, in terms of 100×S2/S1, is 85% or more and 120% or less.

An ion exchange membrane containing: a layer S containing a fluorine-containing polymer having a sulfonic acid group; a layer C containing a fluorine-containing polymer having a carboxylic acid group; and—a plurality of reinforcing materials functioning as at least one of reinforcement yarn and sacrifice yarn; wherein, when the ion exchange membrane is viewed from a top surface, an average cross-sectional thickness A of the ion exchange membrane measured in pure water for a region, is μm or more and 75 μm or less, and wherein a strength change ratio calculated from strength S2 of the ion exchange membrane measured after the ion exchange membrane is subjected to a predetermined electrolysis test and strength S1 of the ion exchange membrane measured before the ion exchange membrane is subjected to the electrolysis test, in terms of 100×S2/S1, is 85% or more and 120% or less.

Membrane assemblies for electrochemical devices are provided, along with methods and system for fabricating them. Membrane assemblies comprise anode layer(s) and cathode layer(s), separated by membranous separation layer(s) and all embedded in continuous polymerized ionomer material. In production, during continuous deposition of ionomer material on a substrate (e.g., by electrospinning or electrospraying), consecutive deposition stages of catalyst material and optionally binder material are performed. For example, anode particles, binder material and cathode particles may be deposited (e.g., by electrospraying or electrospinning, respectively) consecutively during the continuous deposition o the ionomer material. Self-refueling power-generating system are provided, which include reversible anion exchange membrane devices with disclosed membrane assemblies.

An electrolyzer has an electrolytic cell with a membrane that surrounds an interior channel. The electrolytic cell also has a first electrode positioned in the interior channel such that the membrane surrounds the first electrode. The electrolytic cell also includes a second electrode positioned such that the membrane is located between the first electrode and the second electrode.

An electrolyzer has an electrolytic cell with a membrane that surrounds an interior channel. The electrolytic cell also has a first electrode positioned in the interior channel such that the membrane surrounds the first electrode. The electrolytic cell also includes a second electrode positioned such that the membrane is located between the first electrode and the second electrode.

Electrochemical systems, separator plates and methods for production thereof, the separator plate comprising: an active region and at least one first through-opening for supplying a reaction medium to flow channels, and one second through-opening for conducting the reaction medium away from flow channels. At least one through-opening enclosed by a roller-embossed sealing bead. Roller embossing a first layer in a first transportation direction and roller embossing a second layer in a second transportation direction, and arranging the two metal layers opposite one another relative to the respective transportation directions. Two roller-embossed sealing beads are arranged one above the other.

Electrochemical systems, separator plates and methods for production thereof, the separator plate comprising: an active region and at least one first through-opening for supplying a reaction medium to flow channels, and one second through-opening for conducting the reaction medium away from flow channels. At least one through-opening enclosed by a roller-embossed sealing bead. Roller embossing a first layer in a first transportation direction and roller embossing a second layer in a second transportation direction, and arranging the two metal layers opposite one another relative to the respective transportation directions. Two roller-embossed sealing beads are arranged one above the other.

To provide an ion exchange membrane for alkali chloride electrolysis which has a low membrane resistance and which is capable of reducing the electrolysis voltage during the alkali chloride electrolysis, while increasing the membrane strength. An ion exchange membrane 1 for alkali chloride electrolysis wherein a reinforcing material 20 obtained by weaving with reinforcing yarns 22 and sacrificial yarns 24 is embedded in a fluoropolymer having ion exchange groups, the ion exchange membrane 1 comprises elution holes (28) formed by eluting at least a portion of a material of the sacrificial yarns 24, and in a cross section perpendicular to the length direction of the yarns, the total area (S) obtained by adding the cross-sectional area of an elution hole 28 and the cross-sectional area of a sacrificial yarn 24 remaining in the elution hole 28 is from 500 to 1,200 μm.sup.2, and the number (n) of elution holes 28 between adjacent reinforcing yarns 22 is at least 10.