Bifacial sealed gas diffusion electrode

An electrode assembly, comprising:

• a first electrode comprising a planar portion, a bottom peripheral edge, a top peripheral edge, a first lateral peripheral edge, a second lateral peripheral edge, a convex portion, and a raised portion, the planar portion of the first electrode adjacent to each one of the bottom peripheral edge, the first lateral peripheral edge, and the second lateral peripheral edge, the convex portion extending from the planar portion of the first electrode to the raised portion in a central region and extending to the top peripheral edge;
• a second member opposite the first electrode, the second member including a surface, the planar portion of the first electrode contacting and sealed against the surface of the second member, and the first electrode and the second member defining an internal chamber therebetween,
• wherein the second member comprises a second electrode, the second electrode comprises a planar portion, a convex portion, and a raised portion, the planar portion of the second electrode adjacent to the bottom peripheral edge, the first lateral peripheral edge, and the second lateral peripheral edge of the first electrode, the convex portion of the second electrode extending from the planar portion of the second electrode to the raised portion of the second electrode, the raised portion in a central region of the second electrode and extending to the top peripheral edge of the first electrode,
• wherein the first electrode and the second electrode each comprise a respective laminate structure gas diffusion electrode, each laminate structure gas diffusion electrode comprising an active layer and at least one backing layer;
• and
• an insert within the internal chamber and contacting the respective backing layer of each one of the first electrode and the second electrode, the insert defining air flow fields across the respective backing layer of each one of the first electrode and the second electrode.

A method of fabricating an electrode assembly, comprising:

• providing a layer stack comprising at least one active layer and at least one backing layer;
• forming a laminate structure gas diffusion electrode by applying pressure and heat to the layer stack, the laminate structure gas diffusion electrode including a planar portion adjacent to a bottom peripheral edge and first and second lateral peripheral edges of the laminate structure gas diffusion electrode, a convex portion extending from the planar portion to a raised portion of the laminate structure gas diffusion electrode located in a central region and extending adjacent to a top peripheral edge of the laminate structure gas diffusion electrode;
• and
• bonding the laminate structure gas diffusion electrode to a second member to seal the planar portion to the second member and form an electrode assembly having an internal chamber between the laminate structure gas diffusion electrode and the second member.