A clad porous metal substrate for use in a metal-supported electrochemical cell, wherein a metal support layer of defined porosity is clad on top and bottom sides with a layer containing a metal and/or a metal oxide. A metal-supported electrochemical half-cell and a metal-supported electrochemical cell are also described.

A clad porous metal substrate for use in a metal-supported electrochemical cell, wherein a metal support layer of defined porosity is clad on top and bottom sides with a layer containing a metal and/or a metal oxide. A metal-supported electrochemical half-cell and a metal-supported electrochemical cell are also described.

The presently disclosed subject matter relates to devices, systems, and methods of producing an improved fluid flow assembly and liquid/gas diffusion layer in solid polymer electrolyte electrochemical cells. In one aspect, a fluid flow assembly for a polymer electrolyte water electrolyzer includes a flow field having an inlet, an outlet, and a plurality of discrete lands arranged within the flow field. A liquid/gas diffusion layer is positioned in communication with the flow field between the inlet and the outlet, the liquid/gas diffusion layer having a solid substrate through which a plurality of pores is formed. The disclosed bipolar plate flow field and liquid/gas diffusion layer could work together or separately with other types of porous transport layers or bipolar plates to enhance the water/gas transport. In these configurations, the lands can be arranged and configured such that the plurality of pores are substantially unobstructed by the lands.

The presently disclosed subject matter relates to devices, systems, and methods of producing an improved fluid flow assembly and liquid/gas diffusion layer in solid polymer electrolyte electrochemical cells. In one aspect, a fluid flow assembly for a polymer electrolyte water electrolyzer includes a flow field having an inlet, an outlet, and a plurality of discrete lands arranged within the flow field. A liquid/gas diffusion layer is positioned in communication with the flow field between the inlet and the outlet, the liquid/gas diffusion layer having a solid substrate through which a plurality of pores is formed. The disclosed bipolar plate flow field and liquid/gas diffusion layer could work together or separately with other types of porous transport layers or bipolar plates to enhance the water/gas transport. In these configurations, the lands can be arranged and configured such that the plurality of pores are substantially unobstructed by the lands.

A solid oxide fuel cell includes a support of which a main component is a metal, a mixed layer that is provided on the support and includes a metallic material and a ceramics material, an intermediate layer that is provided on the mixed layer and includes an electron conductive ceramics material, and an anode that is provided on the intermediate layer and includes an oxygen ion conductive ceramics material and Ni. A ratio of a metal component in the intermediate layer is smaller than a ratio of the metallic material in the mixed layer.

A bipolar plate with an enhanced fluid flow field design is provided for a fuel cell. The bipolar plate includes an inlet, an outlet, and a flow field having a pattern defining a plurality of microchannels configured to provide fluid communication between the inlet and the outlet. The pattern is designed using an inverse permeability field, and is based on a reaction-diffusion algorithm to model channel spacing, thereby providing a variable pitch microchannel pattern to direct fluid from the inlet to the outlet. In various aspects, the reaction-diffusion algorithm utilize Gray-Scott reaction-diffusion equations, which may be used to obtain an anisotropic microchannel layout. The variable pitch microchannel pattern may include a channel spacing based on effective medium theory.

A bipolar plate with an enhanced fluid flow field design is provided for a fuel cell. The bipolar plate includes an inlet, an outlet, and a flow field having a pattern defining a plurality of microchannels configured to provide fluid communication between the inlet and the outlet. The pattern is designed using an inverse permeability field, and is based on a reaction-diffusion algorithm to model channel spacing, thereby providing a variable pitch microchannel pattern to direct fluid from the inlet to the outlet. In various aspects, the reaction-diffusion algorithm utilize Gray-Scott reaction-diffusion equations, which may be used to obtain an anisotropic microchannel layout. The variable pitch microchannel pattern may include a channel spacing based on effective medium theory.

A fuel cell system includes a first electrically non-conductive sheet portion having a coolant flow layer in an opening thereof, a first non-stamped, flat, metal separator on a first side of the coolant flow layer and a second non-stamped, flat, metal separator on a second side of the coolant flow layer opposite the first separator. A membrane is received in an opening of a second electrically non-conductive sheet portion. Gas diffusion layers are located on opposite sides of the membrane. The gas diffusion layers have channels open toward the first non-stamped, flat, metal separator or the second non-stamped, flat, metal separator to allow flow of an oxidant and/or fuel therethrough.

A fuel cell system includes a first electrically non-conductive sheet portion having a coolant flow layer in an opening thereof, a first non-stamped, flat, metal separator on a first side of the coolant flow layer and a second non-stamped, flat, metal separator on a second side of the coolant flow layer opposite the first separator. A membrane is received in an opening of a second electrically non-conductive sheet portion. Gas diffusion layers are located on opposite sides of the membrane. The gas diffusion layers have channels open toward the first non-stamped, flat, metal separator or the second non-stamped, flat, metal separator to allow flow of an oxidant and/or fuel therethrough.

The present disclosure is directed towards the design of electrochemical cells for use in high pressure or high differential pressure operations. The electrochemical cells of the present disclosure have non-circular external pressure boundaries, i.e., the cells have non-circular profiles. In such cells, the internal fluid pressure during operation is balanced by the axial tensile forces developed in the bipolar plates, which prevent the external pressure boundaries of the cells from flexing or deforming. That is, the bipolar plates are configured to function as tension members during operation of the cells. To function as an effective tension member, the thickness of a particular bipolar plate is determined based on the yield strength of the material selected for fabricating the bipolar plate, the internal fluid pressure in the flow structure adjacent to the bipolar plate, and the thickness of the adjacent flow structure.