COx electrolyzer cell flow fields and gas diffusion layers

1. A method comprising:

causing, at least in part, a stack of layers to be arranged between compressing surfaces of a press, the stack of layers comprising a plurality of gas diffusion layers stacked directly upon one another; and

causing, at least in part, the press to apply one or more compression cycles to the stack of layers to reduce a combined, uncompressed thickness of the plurality of gas diffusion layers by about 2% to about 30%.

2. The method of claim 1 , wherein the combined, uncompressed thickness of the plurality of gas diffusion layers is reduced by about 6% to about 17%.

3. The method of claim 1 , further comprising:

positioning the plurality of gas diffusion layers within an alignment assembly.

4. The method of claim 1 , wherein:

the press is a hot press or a laminator; and

a setpoint temperature of the compressing surfaces is between about 20° C. and about 80° C. during the one or more compression cycles.

5. The method of claim 4 , wherein the stack of layers comprises the plurality of gas diffusion layers arranged between thermally reflective layers.

6. The method of claim 5 , wherein:

each thermally reflective layer among the thermally reflective layers is formed of aluminum, copper, gold, silver, or any combination thereof; and

each thermally reflective layer among the thermally reflective layers has a thickness between about 0.006 mm and about 0.2 mm.

7. The method of claim 5 , wherein the thermally reflective layers form a thermal envelop encasing the gas diffusion layers.

8. The method of claim 1 , wherein the stack of layers comprises the plurality of gas diffusion layers arranged between sacrificial cushion layers.

9. The method of claim 8 , wherein:

the sacrificial cushion layers are formed of polytetrafluoroethylene, chlorotrifluoroethylene (E-CTFE), polyethylene, perfluoroalkoxy (PFA), ethylene tetrafluoroethylene (ETFE), or any combination thereof, and

each sacrificial cushion layer among the sacrificial cushion layers has a thickness of about 0.254 mm to about 0.508 mm.

10. The method of claim 1 , wherein each compression cycle among the compression cycles comprises pressure being progressively applied up to a maximum pressure between about 100 psi and about 400 psi.

11. The method of claim 10 , wherein the maximum pressure is between about 180 psi and about 220 psi.

12. The method of claim 10 , wherein each compression cycle among the compression cycles comprises the maximum pressure being applied for about 2 minutes to about 11 minutes.

13. The method of claim 10 , wherein each compression cycle among the compression cycles comprises the maximum pressure being applied for about 4 minutes to about 6 minutes.

14. The method of claim 1 , wherein the one or more compression cycles causes, at least in part, the plurality of gas diffusion layers to be connected to one another to form a combined gas diffusion layer.

15. The method of claim 1 , wherein the one or more compression cycles causes, at least in part, the plurality of gas diffusion layers to be adhered to one another to form a combined gas diffusion layer.

16. The method of claim 14 , further comprising:

causing, at least in part, the combined gas diffusion layer to be cut or trimmed to a predetermined size.

17. The method of claim 1 , wherein each gas diffusion layer among the gas diffusion layers is a pre-manufactured gas diffusion layer having been previously compressed at least once prior to application of the one or more compression cycles.

18. The method of claim 1 , wherein each gas diffusion layer among the gas diffusion layers comprises a fibrous substrate and a microporous layer.

19. The method of claim 18 , wherein the fibrous substrate is formed of woven carbon cloth, non-woven carbon fiber layers, or carbon fiber papers.

20. The method of claim 18 , wherein the fibrous substrate and/or the microporous layer is treated or coated with a hydrophobic material.