Ozone generation module based on composite electrode

Abstract

The invention relates to the field of ozone generation modules, and particularly discloses an ozone generation module based on a composite electrode, which comprises a cathode wiring terminal, an anode wiring terminal, an anode conducting strip, a composite diamond electrode, a proton exchange membrane and a cathode electrode plate, the composite diamond electrode is composed of a base material layer made of a metal material and boron-doped diamond conducting layers deposited on the two sides of the base material layer respectively, wherein the resistivity of the base material layer is lower than 20 n omega.m. The anode conducting plate is electrically connected with the first conducting layer of the composite diamond electrode to form an anode, and the cathode electrode plate is attached to the surface of the second conducting layer of the composite diamond electrode to form a cathode; the proton exchange membrane is clamped between the composite diamond electrode and the cathode electrode plate, so that the electrolytic reaction can be carried out on the two sides of the composite diamond electrode at the same time.

Description

Technical Field

[0001] This invention relates to the field of ozone generating modules, specifically an ozone generating module based on a composite electrode. Background Technology

[0002] Ozone, due to its advantages of high-efficiency sterilization and residue-free operation, is widely used in portable appliances such as oral irrigators, water faucets, and refrigerator sterilization modules. In recent years, with the rise of boron-doped diamond (BDD) electrodes in the field of electrochemical ozone generation, various "miniaturized electrolytic component" solutions have been proposed both domestically and internationally, among which Chinese patent CN118756166A is the most representative. This patent document adopts a stacked structure: the cathode, solid electrolyte membrane, and anode are all located on the same side of the diamond membrane, and current is extracted by placing a conductive sheet at one end of the anode and injecting silver-based conductive adhesive. Although this solution avoids to some extent the problems of excessive internal resistance caused by excessively high anode substrate resistance in structures where the anode and cathode are placed on opposite sides, it still has the following limitations:

[0003] The cathode and anode are located on the same side of the diamond film. The anode can only be connected to the external power source through a "small sheet-like conductive contact". The contact area is small and the current carrying capacity is limited.

[0004] To compensate for insufficient contact area, conductive adhesive must be filled between the contact and the diamond film. However, the conductive adhesive is prone to aging and increased internal resistance after curing, leading to fluctuations in contact resistance and reduced long-term stability.

[0005] To ensure that the conductive adhesive does not contaminate the active surface of the electrode, precise dispensing of the adhesive is required on the tiny end face and control of curing shrinkage, making it difficult to balance manufacturing tolerance and yield.

[0006] In view of the above-mentioned shortcomings, there is an urgent need to provide a new ozone generating module that can maintain the excellent electrochemical performance of boron-doped diamond while solving technical problems such as small-area conductive contacts, electrode heating and low ozone dissolution efficiency by reducing electrode internal resistance, increasing the effective area of ​​the cathode and simplifying the assembly process. This would meet the market demand for high-efficiency, low-power and long-life ozone generators in portable water treatment and oral hygiene equipment. Summary of the Invention

[0007] The purpose of this invention is to provide an ozone generating module based on a composite electrode to solve the technical problem caused by excessive internal resistance mentioned in the background art.

[0008] The ozone generation module based on composite electrodes includes:

[0009] Cathode terminal, anode terminal, anode conductive sheet, composite diamond electrode, proton exchange membrane and cathode electrode sheet;

[0010] The anode conductive sheet is electrically connected to the first conductive layer of the composite diamond electrode and forms the anode, while the cathode electrode sheet is attached to the surface of the second conductive layer of the composite diamond electrode and forms the cathode.

[0011] The proton exchange membrane is sandwiched between the composite diamond electrode and the cathode electrode sheet.

[0012] Preferably, the composite diamond electrode consists of a substrate layer made of a metallic material and boron-doped diamond conductive layers deposited on one or both sides of the substrate layer.

[0013] Preferably, the resistivity of the substrate layer of the composite diamond electrode is 1-20 nΩ·m;

[0014] Preferably, it further includes an elastic clamping element, which is a wave spring that provides a constant clamping force of 0.05MPa to 0.15MPa along the axial direction to the composite diamond electrode, the proton exchange membrane and the cathode electrode sheet.

[0015] Preferably, the compression stroke of the wave spring is 0.2mm to 1mm.

[0016] Preferably, the device further includes a fixing component for pressing the anode conductive sheet onto the first conductive layer of the composite diamond electrode and fixing the cathode electrode sheet onto the second conductive layer of the composite diamond electrode. The fixing component includes a cathode fixing screw and an anode fixing screw; the anode fixing screw is used to press the anode conductive sheet onto the first conductive layer of the composite diamond electrode, and the cathode fixing screw is used to fix the cathode electrode sheet onto the second conductive layer of the composite diamond electrode.

[0017] Preferably, it further includes a non-metallic isolation block surrounding the outer periphery of the electrode assembly, the non-metallic isolation block being a plastic isolation block, used to electrically isolate the electrode assembly and define fluid channels.

[0018] Preferably, it also includes a non-metallic outer shell and a non-metallic base, wherein the non-metallic outer shell and the non-metallic base are respectively a plastic outer shell and a plastic base, the plastic outer shell and the plastic base form a sealed cavity, and the plastic base is provided with a water flow channel and micro-protrusions on the inner wall to enhance turbulence and improve ozone dissolution efficiency.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] By optimizing the substrate processing technology and adding a transition layer, the problem of tight bonding between boron-doped diamond and low-resistivity substrate was solved. This significantly reduced the overall resistivity of the electrolytic anode to the order of nΩ·m, greatly reduced the overall electrode resistance, and prevented the generation of perceptible Joule heat when current passes through, thereby reducing scale formation and effectively suppressing the temperature rise of the working fluid and maintaining ozone stability.

[0021] The composite diamond film electrode serves as the anode, while the cathode uses a cathode conductive sheet. The cathode area can expand synchronously with the anode, resulting in a more uniform current density distribution, which helps to improve ozone generation efficiency and reduce polarization.

[0022] By using a full-surface metal conductive sheet or clamping component to directly contact the diamond conductive layer, the precision dispensing and curing steps are avoided, simplifying the assembly process and improving contact reliability.

[0023] By replacing tiny end-face contacts with planar pressing, the requirements for the flatness and positioning accuracy of parts are relaxed, the structural thickness can be reduced, the degree of integration is higher, and it is easier to integrate in confined spaces such as portable oral irrigators and water purifiers.

[0024] Because electrode heating is suppressed and the composite layer has excellent chemical inertness, the rates of anodic passivation and cathodic corrosion are significantly slowed down. After long-term operation, the ozone production rate is stable, reducing the frequency of maintenance and replacement. Attached Figure Description

[0025] Figure 1 This is an exploded view of an ozone generating module based on a composite electrode according to Embodiment 1 of the present invention;

[0026] Figure 2 This is a front view of an ozone generating module based on a composite electrode according to Embodiment 1 of the present invention;

[0027] Figure 3 This is a cross-sectional view at point A of an ozone generating module based on a composite electrode according to Embodiment 1 of the present invention;

[0028] Figure 4 This is a cross-sectional view at point B of an ozone generating module based on a composite electrode according to Embodiment 1 of the present invention.

[0029] Figure 5 This is a cross-sectional view at point B of an ozone generating module based on a composite electrode according to Embodiment 2 of the present invention.

[0030] Figure 6 This is a schematic diagram of the conductive layers deposited on both sides of the composite diamond electrode in an ozone generating module based on a composite electrode according to Embodiment 3 of the present invention.

[0031] Figure 7 This is a schematic diagram illustrating the operating principle of an ozone generating module based on a composite electrode according to Embodiment 3 of the present invention.

[0032] Figure 8 This is another schematic diagram illustrating the operating principle of an ozone generating module based on a composite electrode according to Embodiment 3 of the present invention.

[0033] In the diagram: 1. Cathode terminal; 2. Anode terminal; 3. Anode fixing screw; 4. Cathode fixing screw; 5. Anode conductive sheet; 6. Composite diamond electrode; 7. Proton exchange membrane; 8. Cathode electrode sheet; 9. Elastic clamping element; 10. Plastic isolation block; 11. Plastic shell; 12. Plastic base. Detailed Implementation

[0034] Example 1:

[0035] The superconducting electrode-based ozone generating module of the present invention will be described in detail below with reference to the accompanying drawings (Figures 1 to 4) to enable those skilled in the art to manufacture, assemble, and apply it. The dimensions, parameters, and process conditions involved in this embodiment are only used to illustrate the inventive concept and can be adjusted equivalently without departing from the core technical solution of the present invention.

[0036] An ozone generating module based on a composite electrode includes:

[0037] Cathode terminal 1, anode terminal 2, anode conductive sheet 5, composite diamond electrode 6, proton exchange membrane 7, and cathode electrode sheet 8;

[0038] The anode conductive sheet 5 is electrically connected to the first conductive layer of the composite diamond electrode 6 and forms an anode, while the cathode electrode sheet 8 is attached to the surface of the second conductive layer of the composite diamond electrode 6 and forms a cathode.

[0039] The proton exchange membrane 7 is sandwiched between the composite diamond electrode 6 and the cathode electrode plate 8.

[0040] Specifically, the composite diamond electrode 6 consists of a substrate layer made of metal material and a boron-doped diamond conductive layer deposited on one side of the substrate layer.

[0041] Specifically, the resistivity of the substrate layer of the composite diamond electrode 6 is 1-20 nΩ·m;

[0042] Specifically, it also includes an elastic clamping element 9, which is a wave spring that provides a constant clamping force of 0.05MPa to 0.15MPa along the axial direction to the composite diamond electrode 6, the proton exchange membrane 7 and the cathode electrode plate 8.

[0043] Specifically, the compression stroke of the wave spring is 0.2mm to 1mm.

[0044] Specifically, it also includes a fixing component for pressing the anode conductive sheet 5 onto the first conductive layer of the composite diamond electrode 6 and fixing the cathode electrode sheet 8 onto the second conductive layer of the composite diamond electrode (6). The fixing component includes an anode fixing screw 3 and a cathode fixing screw 4. The cathode fixing screw 4 is used to fix the cathode electrode sheet 8 onto the second conductive layer of the composite diamond electrode 6, and the anode fixing screw 4 is used to press the anode conductive sheet 5 onto the first conductive layer of the composite diamond electrode 6.

[0045] Specifically, it also includes a non-metallic isolation block surrounding the electrode assembly, wherein the non-metallic isolation block is a plastic isolation block 10, which is used to electrically isolate the electrode assembly and define the fluid channel.

[0046] Specifically, it also includes a non-metallic shell and a non-metallic base, wherein the non-metallic shell and the non-metallic base are respectively a plastic shell 11 and a plastic base 12, the plastic shell 11 and the plastic base 12 form a sealed cavity, and the plastic base 12 is provided with a water flow channel and micro-convex ribs on the inner wall to enhance turbulence and improve ozone dissolution efficiency.

[0047] The elastic clamping element maintains a constant surface pressure on the proton exchange membrane, preventing contact resistance drift caused by conductive adhesive aging and thermal expansion in contrast technologies. The S-shaped channel, combined with micro-convex ribs, induces turbulence, ensuring thorough mixing of the ozone generated at the anode with the mainstream water, preventing back pressure from air resistance. After the module is shut down, rinsing for 30 seconds is sufficient to remove residual chloride ions and acidic byproducts, eliminating the need for disassembly and maintenance.

[0048] The optimized low-resistivity substrate and BDD thin film configuration reduce the internal resistance of the electrode itself to less than one percent of that of traditional BDD, fundamentally weakening the electrolytic heat source and avoiding ozone thermal decay caused by temperature rise.

[0049] When the conductive layer participates in the reaction, it significantly reduces current density concentration compared to traditional methods, and suppresses polarization, localized electrolyte acidification, and membrane aging.

[0050] Surface contact and spring preload replace micro-dot adhesive, widening the tolerance to ±0.05mm and significantly improving production yield; conductive adhesive is only used for gap filling and no longer undertakes the main current-carrying function, thus improving reliability.

[0051] The composite micro-convex ribs in the base flow channel create periodic disturbances in laminar and turbulent flow, reducing the thickness of the liquid film at the interface and lowering the mass transfer resistance for ozone dissolution; at the same time, the gas-liquid separation range is shortened, reducing the loss of undissolved ozone.

[0052] Based on the above description, those skilled in the art can complete the module preparation and use of the present invention without creative effort, and can make substitutions for the type of metal substrate, the thickness of the BDD membrane, the model of the proton exchange membrane, or the flow channel structure according to actual application requirements.

[0053] Example 2

[0054] like Figure 5

[0055] The composite diamond electrode consists of a substrate layer made of metallic material and boron-doped diamond conductive layers deposited on both sides of the substrate layer.

[0056] Boron-doped diamond is deposited on both sides of a low-resistivity substrate via CVD as an anode, with a cathode conductive sheet disposed on the outside of the anode. The cathode area can expand synchronously with the anode, resulting in a more uniform current density distribution, which helps to improve ozone generation efficiency and reduce polarization.

[0057] During operation, the miniature diaphragm pump continuously delivers materials with a conductivity ≤10µS·cm. -1 Pure water at 80-100 mL / min -1 The flow is pushed into the S-shaped flow channel of the base 12; the DC power supply drives the module with a constant voltage of 6V, and the current passes through the cathode terminal 1, cathode electrode plate 8, proton exchange membrane 7, composite diamond electrode 6, anode conductive plate 5, and anode terminal 2 in sequence. In this invention, the current is shunt on both sides of the composite diamond electrode:

[0058] The BDD film on the anode side is rich in holes, which can generate hydroxyl radicals through high overpotential and further trimerize ozone.

[0059] Hydrogen is generated on the cathode side by a titanium mesh. Under RuO2 / IrO2 bifunctional catalysis, the polarization overpotential is low and the cathode potential is stable.

[0060] Because the intrinsic resistivity of the BDD electrode on the Nb-Ti substrate is much lower than that of traditional BDD, down to the order of nano-ohm, there is no significant ohmic drop between the two films; the current flows symmetrically back in the metal substrate, Joule heat hardly accumulates, and the rise in water temperature is effectively suppressed, which is beneficial to reducing scale deposition and coating peeling.

[0061] Example 3

[0062] like Figure 6-8 In the complex electrode structure of Examples 1 or 2, uneven current distribution occurs during electrolysis, and differences in current density directly affect the heating of different areas of the electrode. When the current distribution is uneven, overheating occurs in local areas. This uneven heat distribution further exacerbates the instability of electrode performance, forming a complex coupling relationship between current distribution and heat changes. Due to the lack of effective internal monitoring methods, this dynamic process cannot be grasped in real time, resulting in a lack of reliable data for the optimized design of the electrode, which seriously restricts the further development of superconducting electrode ozone generation technology.

[0063] Therefore, Example 2 effectively embeds a micro-observation device into the ozone generation module, accurately analyzes the performance of the electrode during the electrolysis process under superconducting support, and provides precise data support for the optimization of electrode structure and operating parameters, which is a key issue in promoting the practical application of superconducting electrode ozone generation technology.

[0064] Reference Figure 5-7 Specifically, it includes:

[0065] S101. Obtain raw data of current density at multiple points on the surface of the composite diamond electrode. Collect real-time current change information of the double-sided conductive layer of the electrode during the electrolysis process through an embedded micro current sensor array. Simultaneously record the timestamp and spatial coordinate parameters of each measurement point to obtain the basic dataset of current distribution on the electrode surface.

[0066] The raw data of current density at multiple points on the surface of the composite diamond electrode are obtained. Real-time current change information of the double-sided conductive layer of the electrode during the electrolysis process is collected by an embedded micro current sensor array. The timestamp and spatial coordinate parameters of each measurement point are recorded simultaneously to obtain the basic dataset of current distribution on the electrode surface.

[0067] S102. Based on the current distribution dataset, a multi-sensor fusion algorithm is used to calculate and analyze the current density difference in different regions inside the electrode. If the current density difference exceeds a preset threshold, it is determined that there is an uneven current distribution phenomenon, and the precise location information and intensity level of the uneven current distribution region on the electrode surface are obtained.

[0068] Based on the current distribution dataset, a multi-sensor fusion algorithm is used to calculate and analyze the current density differences in different regions inside the electrode. If the current density difference exceeds a preset threshold, it is determined that there is an uneven current distribution, and the precise location information and intensity level of the uneven current distribution region on the electrode surface are obtained.

[0069] S103. The temperature change in the uneven current distribution area is monitored in real time by a network of miniature temperature sensors in the superconducting observation system. Heat accumulation data and temperature gradient information of each region of the electrode during the electrolysis reaction are collected to determine the heat distribution pattern and temperature change trend on the electrode surface.

[0070] The temperature changes in the uneven current distribution region are monitored in real time by a network of miniature temperature sensors in the superconducting observation system. Data on heat accumulation and temperature gradient in each region of the electrode during the electrolysis reaction are collected to determine the heat distribution pattern and temperature change trend on the electrode surface.

[0071] S104. Based on the temperature change trend, a correlation model between current density and local temperature is established using a thermoelectric coupling analysis algorithm. If the local temperature rise rate exceeds the safe operating range, a heat anomaly warning mechanism is triggered, and the quantitative analysis results of the electrode thermoelectric coupling characteristics are obtained.

[0072] Based on the temperature change trend, a correlation model between current density and local temperature is established using a thermoelectric coupling analysis algorithm. If the rate of increase in local temperature exceeds the safe operating range, a heat anomaly early warning mechanism is triggered, and quantitative analysis results of electrode thermoelectric coupling characteristics are obtained.

[0073] S105. After obtaining the quantitative analysis results of the thermoelectric coupling characteristics, the working status of different regions of the electrode is evaluated in real time by an adaptive threshold judgment algorithm. If a region has both excessively high current density and abnormal temperature, it is determined that the region has a risk of performance degradation, and the overall performance status of the electrode and potential fault areas are determined.

[0074] After obtaining the quantitative analysis results of the thermoelectric coupling characteristics, the working status of different regions of the electrode is evaluated in real time through an adaptive threshold judgment algorithm. If a region simultaneously shows excessively high current density and abnormal temperature, it is determined that the region has a risk of performance degradation, thus determining the overall performance status of the electrode and potential fault areas.

[0075] S106. Based on the overall performance status evaluation results of the electrode, the voltage distribution and current control strategy in the electrolysis process are adjusted by using a parameter optimization algorithm. The uniformity of current distribution on the electrode surface is improved by dynamically adjusting the current input intensity of each region, thereby obtaining an optimized electrode operating parameter configuration scheme.

[0076] Based on the overall performance status evaluation results of the electrode, a parameter optimization algorithm is used to adjust the voltage distribution and current control strategy during the electrolysis process. By dynamically adjusting the current input intensity of each region, the uniformity of current distribution on the electrode surface is improved, and an optimized electrode operating parameter configuration is obtained.

[0077] S107. Through the optimized operating parameter configuration scheme, the working state of the diamond electrode is adjusted in real time, and the improvement effect of current distribution and temperature change on the electrode surface is continuously monitored. If the current distribution uniformity index reaches the expected standard, the current parameter setting is maintained to obtain the optimal working parameters under the stable operating state of the electrode.

[0078] S108. Based on the long-term operating data of the optimal operating parameters, establish an electrode performance prediction model to predict electrode life and maintenance cycle. By analyzing the historical trends of current distribution and heat change, predict the electrode performance degradation law and determine the data support information for electrode replacement timing and maintenance strategy.

[0079] Based on long-term operating data of the optimal operating parameters, an electrode performance prediction model is established to predict electrode life and maintenance cycle. By analyzing the historical trends of current distribution and heat change, the electrode performance degradation law is predicted, and data support information is provided to determine the electrode replacement timing and maintenance strategy.

[0080] By optimizing the operating parameter configuration scheme, the working state of the diamond electrode is controlled in real time, and the improvement effect of current distribution and temperature change on the electrode surface is continuously monitored. If the current distribution uniformity index reaches the expected standard, the current parameter setting is maintained, and the optimal operating parameters under the stable operating state of the electrode are obtained.

[0081] In S101, when studying the current density distribution on the surface of composite diamond electrodes, high-precision real-time data acquisition can be achieved through an embedded micro-current sensor array. This sensor array typically consists of multiple micro-current probes arranged on the double-sided conductive layer of the electrode to capture dynamic changes in current during electrolysis. Assuming an electrode area of ​​100 square centimeters, the sensor array is distributed in a 5x5 grid, with each probe measuring from 0.1 to 10 mA, covering key areas of the electrode surface. In this way, the current density data at each point can be accurately recorded. For example, in the early stages of electrolysis, points near the electrode edge may show a higher current density, reaching 5 mA per square centimeter, while the central region may only have 2 mA per square centimeter. This difference reflects the non-uniformity of the current distribution on the electrode surface, providing a basis for subsequent optimization design.

[0082] Specifically, synchronously recording timestamps and spatial coordinate parameters is a crucial step in constructing a current distribution dataset. Each sensor point, while acquiring current data, simultaneously records the measurement time and its three-dimensional coordinates on the electrode surface. Assuming the electrolysis experiment lasts 30 minutes and the data acquisition frequency is once per second, each measurement point will generate 1800 data sets, including time, location, and current value. This high-frequency data recording helps capture trends in current changes over time. For example, during electrolysis, periodic fluctuations in current density may be observed at certain points, which could be related to changes in electrolyte concentration or the formation of deposits on the electrode surface. Such a dataset provides comprehensive fundamental information for analyzing electrode performance.

[0083] In practical applications, the design of embedded micro current sensor arrays requires consideration of the characteristics of electrode materials and the complexity of the electrolytic environment. Composite diamond electrodes, due to their high hardness and corrosion resistance, are commonly used in electrolytic experiments under strong acid or alkali conditions; therefore, the sensors must possess chemical corrosion resistance while ensuring measurement accuracy. One possible approach is to use ceramic-encapsulated microsensors to ensure their stability in harsh environments. Furthermore, the sensor density needs to be adjusted based on the electrode size and expected current distribution characteristics. For example, increasing the number of sensors in areas of rapid current change can improve data resolution. This not only enhances the accuracy of data acquisition but also provides more reliable input parameters for modeling the current distribution on the electrode surface.

[0084] Specifically, after obtaining the raw current density data at multiple points on the electrode surface, the relationship between current distribution and electrode performance can be further analyzed.

[0085] By comparing current density data from different regions, it may be discovered that uneven conductive layer thickness in certain areas leads to current concentration, potentially causing localized overheating or electrode wear. To address this issue, electrode manufacturing processes can be optimized or electrolysis conditions adjusted to achieve a more uniform current distribution. This analysis and optimization process not only helps extend electrode lifespan but also improves electrolysis efficiency, reduces energy consumption, and provides technical support for electrochemical reactions in industrial applications. Ultimately, this method based on real-time data acquisition and analysis can significantly improve the design and application performance of composite diamond electrodes.

[0086] In S102, when processing the basic dataset of current distribution on the surface of composite diamond electrodes, a multi-sensor fusion algorithm is used to analyze the differences in current density in different regions within the electrode. Data optimization can be achieved through a combination of weighted averaging and Kalman filtering. Assume a 4×4 array of miniature current sensors is arranged on the electrode surface, with each sensor collecting current density values ​​in milliamperes per square centimeter. At a certain moment, the sensor reading near the electrode edge is 2.3 mA / cm², while the reading in the center region is 1.8 mA / cm². The fusion algorithm calculates the difference, finding the current density difference between the edge and the center to be 0.5 mA / cm². If the preset threshold is 0.4 mA / cm², it is considered an uneven distribution. This method, through the complementarity of multi-sensor data, reduces the influence of noise from a single sensor and improves the accuracy of the analysis.

[0087] Specifically, after determining that the current distribution is uneven, it is necessary to further pinpoint the precise location of the uneven area. One possible approach is to utilize the spatial coordinate parameters of the sensor array, combined with the principle of triangulation, to determine the abnormal area.

[0088] Specifically, the intensity level of the non-uniform region can be determined using a graded quantification method. Assuming the current density difference is divided into three levels: slight (0.4-0.6 mA / cm²), moderate (0.6-0.8 mA / cm²), and severe (>0.8 mA / cm²), a difference of 0.5 mA / cm² can be classified as slight non-uniformity. Further analysis shows that the intensity level of the non-uniform region is related to the electrolyte flow rate; at lower flow rates, the current density in the edge regions is higher. Graded quantification not only clearly reflects the degree of non-uniformity but also provides intuitive guidance for process adjustments, such as homogenizing the current distribution by increasing the flow rate.

[0089] During electrolysis, sensors may drift due to temperature changes. Dynamic correction using a fusion algorithm can control this drift error to within 5%. This correction ensures the stability of current density difference analysis, making it particularly suitable for long-term electrolysis scenarios. The fusion algorithm can also combine historical datasets to predict potential non-uniform regions and optimize electrode layout in advance.

[0090] Specifically, the results of positioning and classification can be presented through a visual interface.

[0091] A thermal map of the electrode surface is generated, with red indicating severely uneven areas and green indicating uniform areas. If the thermal map shows the electrode edges consistently appearing red, it suggests the need to adjust the electrode thickness or the conductive layer material. This visualization method intuitively reflects the current distribution, facilitating rapid decision-making by technicians.

[0092] The fusion algorithm improves data quality, accurate positioning relies on high-quality data, and hierarchical quantization provides application directions for the positioning results. This multi-level analysis ensures efficient identification of uneven current distribution problems, providing solid support for electrode performance optimization.

[0093] In S103, a network of miniature temperature sensors within the superconducting observation system monitors temperature changes in regions with uneven current distribution on the electrode surface in real time. This effectively acquires data on heat accumulation and temperature gradients during the electrolysis reaction, thereby determining the heat distribution pattern and temperature change trend. The following analysis and examples cover multiple technical topics, focusing on the thermal distribution characteristics of the electrode surface to ensure close relevance to the field of current distribution analysis.

[0094] Specifically, assuming a temperature gradient of 0.5 degrees Celsius / cm is detected in the upper left corner of the electrode, significantly higher than the 0.2 degrees Celsius / cm gradient in other areas, and considering the sensor coordinates, it can be inferred that the heat concentration in this area is related to anomalies in current density. Gradient analysis can pinpoint the exact location of these thermal anomalies, providing a basis for optimizing the conductivity of the electrode surface.

[0095] The heat distribution pattern can be established through cluster analysis. Suppose that after processing the sensor data, three main heat distribution patterns are found on the electrode surface: a high-temperature region at the edge, a stable region at the center, and a transition region. The average temperature of the high-temperature region at the edge is 46 degrees Celsius, the average temperature of the stable region at the center is 42 degrees Celsius, and the average temperature of the transition region is 44 degrees Celsius. This pattern analysis helps to intuitively understand the heat distribution law and thus infer the current distribution characteristics.

[0096] Temperature trend prediction can be achieved by combining historical data and machine learning models. Assuming temperature data from the previous 10 electrolysis experiments, the model predicts that under high current density, the temperature in the edge region will exceed 50 degrees Celsius within 20 minutes. This early warning allows for timely adjustments to the electrolyte flow rate or electrode design, preventing overheating and performance degradation. This predictive method enhances the system's proactive optimization capabilities.

[0097] Understandably, the combination of the above methods forms a complete heat distribution analysis chain, from temperature data acquisition to gradient analysis, and then to pattern establishment and trend prediction, with each link supporting the others. Through high-precision sensor networks and data processing technology, the heat distribution characteristics of the electrode surface can be effectively identified, providing a scientific basis for optimizing electrode performance.

[0098] In S104, a thermoelectric coupling analysis algorithm is used to establish a correlation model between current density and local temperature, which can effectively quantify the thermoelectric properties of the electrode surface. In the electrolysis reaction, the current density distribution directly affects the local temperature change. Assuming a composite diamond electrode is used, with an electrode surface size of 10 cm × 10 cm and an operating current density range of 0.1 to 1 A / cm², the thermoelectric coupling analysis algorithm, based on the principles of heat conduction and electrochemical reaction characteristics, constructs a mapping relationship between current density and temperature. In principle, areas with high current density generate more heat due to the Joule heating effect, leading to an increase in local temperature.

[0099] At the electrode edge region, the local temperature reaches 47.5 degrees Celsius when the current density is 0.8 A / cm², while in the central region, the temperature is only 43.2 degrees Celsius when the current density is 0.4 A / cm². The algorithm generates a thermoelectric coupling model by fitting historical data, quantifying the nonlinear relationship between the two and providing a basis for subsequent early warning of thermal anomalies.

[0100] The heat anomaly early warning mechanism is triggered based on a temperature rise rate threshold. Assume the safe operating range specifies a temperature rise rate not exceeding 0.5 degrees Celsius per minute. During electrolysis, the sensor network detects that the temperature in a certain area of ​​the electrode rises from 40 degrees Celsius to 44 degrees Celsius within 5 minutes, at a rise rate of 0.8 degrees Celsius per minute, exceeding the threshold. The early warning mechanism is then triggered, recording the coordinates of this area and marking it as a heat anomaly point.

[0101] The early warning system can analyze the correlation between the rate of temperature rise and current density to infer that abnormal areas may have electrode material defects or uneven electrolyte flow fields, prompting adjustments to the electrolyte flow rate or optimization of the electrode design. This mechanism, through real-time monitoring and rapid response, helps protect electrodes from overheating damage.

[0102] The quantitative analysis results of thermoelectric coupling characteristics provide data support for optimizing electrode performance.

[0103] Specifically, the analysis results show that the thermoelectric coupling coefficient at the electrode edge is 0.65, while it is 0.45 in the central region, indicating that the edge region is more sensitive to the thermal response of current density. By combining the spatial data of the sensor network, the quantification results can be further used to plot the thermoelectric characteristic distribution map, intuitively showing the differences in thermoelectric behavior in different regions of the electrode surface.

[0104] In S105, after obtaining the quantitative analysis results of thermoelectric coupling characteristics, the working status of different regions of the electrode can be evaluated in real time using an adaptive threshold judgment algorithm. The core of this process lies in dynamically adjusting the judgment criteria by combining current density and temperature data to adapt to changes in the electrode's operating environment. In principle, the adaptive threshold judgment algorithm sets a dynamic warning range based on historical operating data and real-time monitoring results, rather than a fixed value, thus better reflecting actual operating conditions. For example, in electrolysis, the electrode edge region may exhibit a higher thermal response due to current concentration. In this case, the algorithm will appropriately increase the temperature anomaly threshold based on the historical characteristic data of that region to avoid misjudgment.

[0105] To determine the risk of performance degradation in a region where both excessively high current density and abnormal temperature are observed simultaneously, a specific implementation method can be used as follows: Assume the electrode surface size is 10 cm × 10 cm, the designed operating current density range is 0.1 to 1 A / cm², and the normal temperature range is 40 to 45 degrees Celsius. Monitoring revealed that the current density in one corner of the electrode reached 1.2 A / cm², exceeding the design limit, while the temperature in this area rose to 48 degrees Celsius, significantly higher than the normal range. The algorithm, combining these two indicators, determines that this region may face performance degradation risks due to material fatigue or uneven local current distribution. This cross-validation using dual indicators makes the evaluation results more reliable and helps to identify potential problems early.

[0106] When determining the overall performance status of electrodes and potential fault areas, analysis can be conducted from multiple perspectives to support the judgment. One approach is to combine spatial distribution data to create thermal maps of current density and temperature across different regions of the electrode surface, visually indicating the location of abnormal areas. For example, if the thermal map shows abnormal indicators at three consecutive monitoring points on the electrode edge, the algorithm will mark that area as a potential fault zone. Another approach is to introduce a time dimension analysis to observe whether the abnormal indicators persist. For instance, if the area maintains high current density and high temperature for 30 consecutive minutes, it is further confirmed as a high-risk fault zone. This multi-dimensional analysis improves the comprehensiveness of the assessment, reduces the possibility of misjudgment based on single data points, and provides precise location support for subsequent maintenance.

[0107] In practical applications, after identifying potential fault areas, historical data can be used to infer the causes of degradation. For example, if anomalies repeatedly occur in a certain area, it may be related to local defects in the electrode material or uneven electrolyte flow field. By analyzing the thermoelectric coupling characteristics data of this area, combined with operating logs, a reference basis can be provided for subsequent optimization design. This method not only identifies problems in a timely manner but also accumulates data support for process improvement.

[0108] To further improve the monitoring accuracy, parameter control rationality, and lifespan prediction accuracy of the ozone generation module electrodes during operation, a dynamic adjustment factor α was introduced.

[0109] The dynamic adjustment factor α is the ratio of the non-uniformity of the electrode surface current distribution to the temperature response sensitivity:

[0110]

[0111] This represents the deviation between the local current density and the average current density.

[0112] The average current density on the electrode surface;

[0113] This represents the deviation between the local temperature and the average temperature.

[0114] The average temperature of the electrode surface;

[0115] This reflects the degree of coupling between the current distribution on the electrode surface and the temperature gradient during operation. When the value of α is large, it indicates that the current deviation contributes more significantly to the temperature response, and the system should pay more attention to the influence of temperature changes; when the value of α is small, it indicates that the weight of the temperature deviation in the overall electrode state is reduced, and the regulation of the current distribution is more critical.

[0116] In the thermoelectric coupling analysis, a comprehensive thermoelectric coupling index function X is constructed:

[0117]

[0118] in, It indicates the rate of temperature rise, reflecting the speed at which heat accumulates in a local area;

[0119] J represents the current density, which reflects the intensity of the local electrochemical reaction at the electrode.

[0120] This formula achieves adaptive fusion of temperature change and current distribution through the intervention of α. When α is close to 1, the formula is more biased towards the weight of the rate of temperature change, and the value of X can quickly reflect the risk of local overheating; when α is close to 0, the formula focuses more on the change of current density, and X can be used to identify anomalies caused by uneven current distribution.

[0121] In the electrode edge region, the current density is often higher than in the center region, resulting in a faster temperature rise rate. By dynamically adjusting α, X can detect abnormal trends earlier, avoiding delayed warnings.

[0122] Unified multi-source information: The two physical quantities of temperature and current are integrated into a single index, avoiding the fragmentation problem of relying on dual threshold judgment (temperature threshold and current threshold exist independently).

[0123] When the electrolyte concentration increases or the flow rate decreases, the relationship between the temperature rise rate and the current density will change. α can be automatically adjusted according to the operating conditions to ensure that X always remains accurate.

[0124] In the threshold judgment process, an operational risk assessment index is constructed:

[0125] Y=α×J max +(1−α)×T max

[0126] Among them, J max This represents the instantaneous peak value of the current density;

[0127] T max This represents the instantaneous peak temperature.

[0128] In traditional methods, peak current and peak temperature are typically monitored independently, each with its own fixed threshold. However, in actual operation, peak temperature and peak current often exhibit a correlation. For example, if the peak current is too high, the peak temperature will also rise. By introducing α, the two are merged into a single index Y, thereby simplifying the judgment logic.

[0129] Traditional methods may generate false alarms when the temperature rises slightly but the current remains within the normal range. This formula avoids this situation by adjusting α, thus improving the reliability of the judgment.

[0130] Since α is derived from the ratio of the deviation between current and temperature, its value can vary with the operating environment. The threshold of Y is not fixed but dynamically adjusted, which is closer to the actual operating conditions.

[0131] The value of Y can be directly used as an indicator of risk level. For example, when Y exceeds a set threshold, it indicates that there is a comprehensive anomaly in a certain area of ​​the electrode, without needing to examine the extreme values ​​of current and temperature separately.

[0132] In S106, based on the overall performance evaluation of the electrode, a parameter optimization algorithm is used to adjust the voltage distribution and current control strategies during the electrolysis process. This effectively improves the uniformity of current distribution on the electrode surface, thereby obtaining an optimized operating parameter configuration scheme. The following analysis and examples illustrate the specific implementation methods from multiple perspectives, focusing on electrode performance optimization in the electrolysis process to ensure that the content is closely aligned with the business domain.

[0133] In the optimization and prediction phase, a performance optimization index is constructed:

[0134]

[0135] X comes from thermoelectric coupling analysis;

[0136] Y is determined by a threshold;

[0137] The α+1 in the denominator is used to prevent α from causing Z to be over-amplified in extreme cases.

[0138] Z combines the first two indicators, including both dynamic process information (X) and extreme value determination information (Y). By multiplying the two, the true abnormal signal can be amplified; by adjusting the denominator, the spurious amplification effect caused by noise is suppressed.

[0139] Z, as a unified performance evaluation quantity, can be directly input into the controller as a feedback signal to adjust the voltage and current distribution strategy in real time, thereby achieving uniform control of the electrode surface.

[0140] By recording the changing trend of Z during long-term operation, the degradation rate and lifespan of the electrode can be predicted more accurately.

[0141] The construction of Z means that the entire system forms a closed loop from monitoring to judgment to optimization, avoiding the disconnect between monitoring and optimization in existing technologies.

[0142] By repeatedly introducing α into the three formulas X, Y, and Z, this embodiment achieves the following innovative effects:

[0143] The presence of α makes the three major links of thermoelectric coupling analysis, threshold judgment and optimization prediction intrinsically linked, rather than operating independently.

[0144] Since α originates from the real-time monitoring of the current-temperature deviation ratio, its value changes with the operating conditions, thus giving the entire system an adaptive capability.

[0145] α serves as the dominant factor throughout, achieving the mathematical fusion of three types of indicators: temperature, current, and threshold, thus solving the problem of parameter fragmentation in traditional methods.

[0146] In S107, the core of optimizing the operating parameters of the composite diamond electrode and real-time control lies in acquiring data on the current distribution and temperature changes on the electrode surface through a dynamic monitoring system to ensure stable operation of the electrode under complex working conditions. The real-time monitoring system typically includes a high-precision current sensor and a temperature probe, capable of capturing the current density and temperature fluctuations in various regions of the electrode surface.

[0147] In S108, the core of constructing an electrode performance prediction model based on long-term operational data of composite diamond electrodes lies in integrating historical monitoring data and analyzing the changing trends of key parameters. Long-term operational data typically includes data points from multiple dimensions such as current distribution, temperature fluctuations, and electrolyte flow field state. The data collection period may be daily or hourly, and the data is stored in the system database. The prediction model identifies potential degradation patterns in electrode performance by analyzing these historical trends.

[0148] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A composite electrode-based ozone generation module, characterized by, It comprises a cathode terminal (1), an anode terminal (2), an anode conductive sheet (5), a composite diamond electrode (6), a proton exchange membrane (7) and a cathode electrode sheet (8). The anode conductive sheet (5) is electrically connected with the first conductive layer of the composite diamond electrode (6) and constitutes an anode, and the cathode electrode sheet (8) is attached to the surface of the second conductive layer of the composite diamond electrode (6) and constitutes a cathode. The proton exchange membrane (7) is clamped between the composite diamond electrode (6) and the cathode electrode sheet (8). The composite diamond electrode (6) is composed of a substrate layer made of a metal material and a boron-doped diamond conductive layer deposited on one side or both sides of the substrate layer.

2. The ozone generation module based on a composite electrode according to claim 1, characterized in that The resistivity of the substrate layer of the composite diamond electrode (6) is 1-20 nΩ·m.

3. The ozone generation module based on a composite electrode according to claim 2, characterized in that It also comprises an elastic compression member (9) which provides a constant compression force of 0.05 MPa-0.15 MPa for the composite diamond electrode (6), the proton exchange membrane (7) and the cathode electrode sheet (8) in the axial direction.

4. The ozone generation module based on a composite electrode according to claim 1, characterized in that The compression stroke of the elastic compression member is 0.2 mm-1 mm.

5. The ozone generation module based on a composite electrode according to claim 4, characterized in that It also comprises a fixing member for pressing and holding the anode conductive sheet (5) on the first conductive layer of the composite diamond electrode (6) and fixing the cathode electrode sheet (8) on the second conductive layer of the composite diamond electrode (6).

6. The ozone generation module based on a composite electrode according to claim 5, characterized in that It also comprises a non-metallic isolation block arranged around the outer periphery of the electrode group for electrically isolating the electrode group and defining a fluid passage.

7. The ozone generation module based on a composite electrode according to claim 6, characterized in that It also comprises a non-metallic shell and a non-metallic base, which form a sealed cavity, and a water flow passage is arranged in the non-metallic base, and a micro-convex rib is arranged on the inner wall to enhance turbulent flow and improve ozone dissolution efficiency.

8. The ozone generation module based on a composite electrode according to claim 7, characterized in that The module introduces a dynamic adjustment factor in the controller to construct comprehensive thermoelectric coupling indexes, risk judgment indexes and comprehensive optimization indexes, respectively, so that the temperature change rate and the current density, the temperature peak value and the current peak value are fused in a unified parameter system.

9. The ozone generation module based on a composite electrode according to claim 8, characterized in that ​

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