Porous transport layer for electrochemical cells

An electrolyzer having at least one electrochemical cell, comprising:

• a membrane electrode assembly in the at least one electrochemical cell, the membrane electrode assembly including
• a first electrode layer including an anode layer;
• a second electrode layer including a cathode layer;
• a polymer electrolyte membrane extending between the first electrode layer and the second electrode layer;
• a first porous transport layer adjacent to the first electrode layer, wherein the first porous transport layer includes:
• a first surface having a planar configuration, wherein the first surface faces the first electrode layer;
• and
• a second surface including embossed features, wherein the second surface faces a first separator plate, and wherein the second surface is configured to facilitate water transport;
• a second porous transport layer adjacent to the second electrode layer;
• the first separator plate disposed adjacent to the first porous transport layer;
• and
• a second separator plate disposed adjacent to the second porous transport layer.

A process, comprising:

• mixing titanium powder with adhesive powder and at least one lubricant to provide brittle titanium particles in a slurry;
• providing the slurry to a die, wherein a first surface of the die is planar, and a second surface of the die includes embossing features configured to form embossed features on a porous transport layer;
• compacting the slurry under high pressure with the die to form a green compact;
• and
• sintering the green compact to form a titanium felt configured to function as a porous transport layer in a polymer electrolyte membrane electrolysis cell.