BIFACIAL SEALED GAS DIFFUSION ELECTRODE
Systems and methods of the various embodiments may provide bifacial sealed gas diffusion electrode (GDE) assemblies. In some embodiments, a bifacial sealed gas diffusion electrode (GDE) assembly includes active electrode layers on two opposing sides of the assembly. Various embodiments may provide architecture and/or sealing methods for GDE assemblies. In various embodiments, the GDE assemblies may be for use in devices. In various embodiments, the devices may be primary or secondary batteries. In various embodiments, these devices may be useful for energy storage. For example, bifacial sealed GDE assemblies of the various embodiments may form cathode electrodes (sometimes called air electrodes) of a battery, such as a metal-air battery.
1 . A method of fabricating a gas diffusion electrode, the method comprising:
folding together an unlaminated portion of a first layer stack and an unlaminated portion of a second layer stack to couple the first layer stack and the second layer stack at interlocking edges, the first layer stack including at least one first active layer and at least one first backing layer, the second layer stack including at least one second active layer and at least one second back layer; and
bonding the interlocking edges into a seam securing the first layer stack to the second layer stack.
2 . The method of claim 1 , wherein the interlocking edges couple the first layer stack and the second layer stack are parallel to one another.
3 . The method of claim 1 , wherein the seam secures the first layer stack to the second layer stack with the first layer stack and the second layer stack parallel to one another.
4 . The method of claim 1 , wherein bonding the interlocking edges includes applying pressure and heat to the interlocking edges includes compressing the interlocking edges to a pressure of at least about 400 psi while heating the interlocking edges to a temperature of at least about 300° C.
5 . The method of claim 1 , wherein the seam is continuous along at least three edges of the first layer stack interlocked with the second layer stack.
6 . The method of claim 5 , wherein the seam forms a pouch open along only one side of the first layer stack interlocked with the second layer stack.
7 . The method of claim 1 , wherein the seam between the first layer stack and the second layer stack is a liquid-tight seal.
8 . The method of claim 1 , wherein the first layer stack further includes a first current collector, and the second layer stack further includes a second current collector.
9 . The method of claim 8 , wherein the at least one first active layer of the first layer stack includes a pair of first active layers, the at least one second active layer of the second layer stack includes a pair of second active layers, the first current collector is disposed between the pair of first active layers, and the second current collector is disposed between the pair of second active layers.
10 . The method of claim 8 , wherein the at least one first backing layer and the at least one second backing layer are each gas diffusion layers.
11 . A method of fabricating an electrode assembly, the method comprising:
forming a first layer stack into a first laminate structure gas diffusion electrode, the first layer stack including a first layer stack including at least one first active layer;
forming a second layer stack into a second laminate structure gas diffusion electrode, the second layer stack including a second layer stack including at least one second active layer;
with a spacer therebetween, bonding the first laminate structure gas diffusion electrode to the second laminate structure gas diffusion electrode; and
removing the spacer from the electrode assembly to define a cavity in the electrode assembly between the first laminate structure gas diffusion electrode and the second laminate structure gas diffusion electrode.
12 . The method of claim 11 , wherein forming the first layer stack into the first laminate structure gas diffusion electrode includes applying pressure and heat to the first layer stack.
13 . The method of claim 11 , wherein forming the second layer stack into the second laminate structure gas diffusion electrode includes applying pressure and heat to the first layer stack.