Flow structures for use with an electrochemical cell
First Claim
1. A flow structure for use in an electrochemical cell, comprising:
- a compacted porous metallic substrate having a void volume greater than about 55% and yield strength greater than about 12,000 psi, wherein the compacted porous metallic substrate is formed by;
selecting a porous metallic substrate with a void volume between about 75% and about 98%; and
compacting uniformly the porous metallic substrate causing plastic deformation and thereby forming the compacted porous metallic substrate and increasing the yield strength to greater than about 12,000 psi;
at least one micro-porous material layer laminated on one side of the compacted porous metallic substrate, wherein an average pore size of the at least one micro-porous material layer is smaller than an average pore size of the compacted porous metallic substrate.
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Abstract
The design and method of fabrication of a three-dimensional, porous flow structure for use in a high differential pressure electrochemical cell is described. The flow structure is formed by compacting a highly porous metallic substrate and laminating at least one micro-porous material layer onto the compacted substrate. The flow structure provides void volume greater than about 55% and yield strength greater than about 12,000 psi. In one embodiment, the flow structure comprises a porosity gradient towards the electrolyte membrane, which helps in redistributing mechanical load from the electrolyte membrane throughout the structural elements of the open, porous flow structure, while simultaneously maintaining sufficient fluid permeability and electrical conductivity through the flow structure.
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Citations
14 Claims
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1. A flow structure for use in an electrochemical cell, comprising:
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a compacted porous metallic substrate having a void volume greater than about 55% and yield strength greater than about 12,000 psi, wherein the compacted porous metallic substrate is formed by; selecting a porous metallic substrate with a void volume between about 75% and about 98%; and compacting uniformly the porous metallic substrate causing plastic deformation and thereby forming the compacted porous metallic substrate and increasing the yield strength to greater than about 12,000 psi; at least one micro-porous material layer laminated on one side of the compacted porous metallic substrate, wherein an average pore size of the at least one micro-porous material layer is smaller than an average pore size of the compacted porous metallic substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. An electrochemical cell for use in high differential pressure operations, comprising:
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a first electrode, a second electrode, and a proton exchange membrane disposed therebetween; a first flow structure in fluid and electrical communication with the first electrode, comprising; a first compacted porous metallic substrate having a void volume greater than about 55% and yield strength greater than about 12,000 psi, wherein the first compacted porous metallic substrate is formed by; selecting a porous metallic substrate with a void volume between about 75% and about 98%; and compacting uniformly the porous metallic substrate causing plastic deformation and thereby forming the first compacted porous metallic substrate and increasing the yield strength to greater than about 12,000 psi; at least one micro-porous material layer laminated on one side of the compacted porous metallic substrate, wherein an average pore size of the at least one micro-porous material layer is smaller than an average pore size of the compacted porous metallic substrate; and a second flow structure comprising a second porous metallic substrate, wherein the second flow structure is in fluid and electrical communication with the second electrode. - View Dependent Claims (13, 14)
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Specification