Stacked Dual Cathode Device

Abstract

This disclosure provides systems, methods, and apparatus related to a stacked dual cathode device. In one aspect, a device includes an anode chamber and a cathode chamber. The anode chamber includes an anode layer. The cathode chamber includes a first cathode layer and a second cathode layer. The device further includes an ion exchange membrane. The anode layer is in contact with a first side of the ion exchange membrane. A first side of the first cathode layer is in contact with a second side of the ion exchange membrane. The cathode chamber further includes a conductive membrane. A first side of the conductive membrane is in contact with a second side of the first cathode layer and a second side of the conductive membrane is in contact with a first side of the second cathode layer.

What is claimed is: 
     
         1 . A device comprising:
 an anode chamber, the anode chamber including an anode layer including an anode catalyst, the anode chamber further including a first anode port operable to admit an oxidation reactant and a second anode port operable to exhaust oxygen;   a cathode chamber, the cathode chamber including a first cathode layer and a second cathode layer, the first cathode layer including a first cathode catalyst and the second cathode layer including a second cathode catalyst, the cathode chamber further including a first cathode port operable to admit a reduction reactant and a second cathode port operable to exhaust a final product; and   an ion exchange membrane, the anode layer being in contact with a first side of the ion exchange membrane, and a first side of the first cathode layer being in contact with a second side of the ion exchange membrane; and   the cathode chamber further including a conductive membrane, the conductive membrane operable to conduct electrons and to conduct ions, a first side of the conductive membrane being in contact with a second side of the first cathode layer and a second side of the conductive membrane being in contact with a first side of the second cathode layer.   
     
     
         2 . The device of  claim 1 , wherein when the device is in operation, the reduction reactant flows through the first cathode layer where it is reduced to a first reduction product, the first reduction product flows to an open volume on an edge of the first cathode layer, the conductive membrane, and the second cathode layer, and the first reduction product then flows through the second cathode layer where it is reduced to the final product. 
     
     
         3 . The device of  claim 1 , wherein an entire first surface of the first cathode layer is in contact with the ion exchange membrane, wherein an entire second surface of the first cathode layer is in contact with the conductive membrane, wherein an entire first surface of the second cathode layer is in contact with the conductive membrane, and wherein an entire second surface of the second cathode layer is in contact with a surface of the device. 
     
     
         4 . The device of  claim 1 , wherein the first cathode port includes a port in the ion exchange membrane, wherein an entire first surface of the first cathode layer except for an area of the port in the ion exchange membrane is in contact with the ion exchange membrane, wherein an entire second surface of the first cathode layer is in contact with the conductive membrane, wherein an entire first surface of the second cathode layer is in contact with the conductive membrane, and wherein an entire second surface of the second cathode layer except for an area of the second cathode port is in contact with a surface of the device. 
     
     
         5 . The device of  claim 1 , wherein the first cathode port includes a port in the ion exchange membrane. 
     
     
         6 . The device of  claim 1 , wherein the ion exchange membrane is a membrane from a group a cation exchange membrane, an anion exchange membrane, and a bipolar membrane. 
     
     
         7 . The device of  claim 1 , wherein the conductive membrane comprises a mixture of an ion exchange polymer and a conductive polymer. 
     
     
         8 . The device of  claim 1 , wherein the first cathode layer comprises a porous material with the first cathode catalyst disposed thereon. 
     
     
         9 . The device of  claim 1 , wherein the second cathode layer comprises a porous material with the second cathode catalyst disposed thereon. 
     
     
         10 . The device of  claim 1 , wherein the first cathode layer and the second cathode layer are each a layer from a group carbon cloth, carbon felt, carbon paper, a metal foam, and a metal mesh. 
     
     
         11 . The device of  claim 1 , wherein the first cathode layer and the second cathode layer are each about 50 microns to 450 microns thick. 
     
     
         12 . The device of  claim 1 , wherein the first cathode catalyst is disposed on the second side of the first cathode layer, and wherein the second cathode catalyst is disposed on the first side of the second cathode layer. 
     
     
         13 . The device of  claim 1 , wherein a layer of a material comprising the ion exchange membrane is disposed on the first side of the first cathode layer. 
     
     
         14 . The device of  claim 1 , wherein the anode layer comprises a porous material with the anode catalyst disposed thereon. 
     
     
         15 . The device of  claim 1 , wherein the anode catalyst comprises an oxygen evolution reaction catalyst. 
     
     
         16 . The device of  claim 1 , wherein the anode layer is about 50 microns to 450 microns thick. 
     
     
         17 . The device of  claim 1 , wherein the anode layer is a layer from a group carbon cloth, carbon felt, carbon paper, a metal foam, and a metal mesh. 
     
     
         18 . The device of  claim 1 , wherein the anode layer has a first side and a second side, wherein the anode catalyst is disposed on the second side of the anode layer, and wherein the second side of the anode layer is in in contact with the first side of the ion exchange membrane. 
     
     
         19 . The device of  claim 1 , wherein the oxidation reactant comprises water. 
     
     
         20 . The device of  claim 1 , wherein the first cathode catalyst comprises silver or gold, wherein the second cathode catalyst comprises copper, wherein the reduction reactant comprises carbon dioxide (CO 2 ), wherein the first product comprises carbon monoxide (CO), and wherein the final product comprises ethylene (C 2 H 4 ).