Flow field alkaline electrolyzer and method of manufacture

Abstract

An electrolyzer can include one or more electrolyzer cells where each electrolyzer cell can include an anode, an anolyte transport layer, a cathode, a catholyte transport layer, and a separator. At least one of the anolyte transport layer and the catholyte transport layer is preferably a flow based transport layer.

We claim: 
     
         1 . An alkaline electrolyzer comprising:
 a set of electrolyzer cells, wherein each electrolyzer cell comprises:
 a basic anolyte; 
 a basic catholyte; 
 a cathode; 
 an anode; 
 an anolyte transport plate, wherein a material of the anolyte transport plate is between 100 and 200 microns thick, wherein the anolyte transport plate comprises:
 a flow channel, wherein the flow channel comprises a depth between 0.01 mm and 5 mm and a width between 2 mm and 15 mm, wherein anolyte within the flow channel contacts the anode; and 
 
 a catholyte transport plate facilitating contact between the cathode and the catholyte; and 
 a separator; wherein the set of electrolyzer cells form an electrolyzer stack. 
   
     
     
         2 . The alkaline electrolyzer of  claim 1 , wherein the flow channel is boustrophedonic. 
     
     
         3 . The alkaline electrolyzer of  claim 1 , wherein the flow channel is serpentine. 
     
     
         4 . The alkaline electrolyzer of  claim 1 , wherein the flow channel is a spiral. 
     
     
         5 . The alkaline electrolyzer of  claim 1 , wherein the flow channels is a double-armed Archimedean spiral. 
     
     
         6 . The alkaline electrolyzer of  claim 1 , wherein the flow channel is wider proximal a middle of the flow channel, wherein a maximum width of the flow channel exceeds a minimum width of the flow channel by a value between 0.5 mm and 4 mm. 
     
     
         7 . The alkaline electrolyzer of  claim 1 , wherein the flow channel is deeper proximal a middle of the flow channel, wherein a maximum depth of the flow channel exceeds a minimum depth of the flow channel by a value between 0.01 mm and 2 mm. 
     
     
         8 . The alkaline electrolyzer of  claim 1 , wherein the anolyte transport plate further comprises a plurality of flow channels. 
     
     
         9 . The alkaline electrolyzer of  claim 8 , wherein the plurality of flow channels are parallel. 
     
     
         10 . The alkaline electrolyzer of  claim 8  wherein the plurality of flow channels are equally spaced. 
     
     
         11 . The alkaline electrolyzer of  claim 8 , wherein the plurality of flow channels are unequally spaced. 
     
     
         12 . The alkaline electrolyzer of  claim 8 , wherein channels proximal a center of the anolyte transport plate have a larger radius of curvature than channels proximal a periphery of the anolyte transport plate. 
     
     
         13 . The alkaline electrolyzer of  claim 1 , wherein the anolyte transport plate is substantially the same as the catholyte transport plate. 
     
     
         14 . The alkaline electrolyzer of  claim 1 , wherein the anolyte transport plate is different from the catholyte transport plate. 
     
     
         15 . The alkaline electrolyzer of  claim 14 , wherein the catholyte transport plate comprises a porous structure. 
     
     
         16 . The alkaline electrolyzer of  claim 1 , wherein the anolyte transport plate does not comprise a porous structure between the flow channel and the anode. 
     
     
         17 . The alkaline electrolyzer of  claim 1 , wherein the catholyte transport plate and the anolyte plate each comprise a flow direction, wherein the flow direction of the catholyte transport plate is substantially aligned with the flow direction of the anolyte transport plate. 
     
     
         18 . The alkaline electrolyzer of  claim 1 , wherein the catholyte transport plate and the anolyte transport plate each comprise a flow direction, wherein the flow direction of the catholyte transport plate is anti-aligned with the flow direction of the anolyte transport plate. 
     
     
         19 . The alkaline electrolyzer of  claim 1 , wherein the catholyte transport plate and the anolyte plate each comprise a flow direction, wherein the flow direction of the catholyte transport plate is perpendicular with the flow direction of the anolyte transport plate. 
     
     
         20 . The alkaline electrolyzer of  claim 1 , wherein the anolyte transport plate further comprises an inlet manifold positioned at the entrance of the flow channel and an outlet manifold positioned at the exit of the flow channel, wherein the inlet manifold has an inlet flow path longer than 100 mm, wherein the outlet manifold has an outlet flow path longer than 100 mm.