Electrolytic cell stack manufacturing method and electrolytic cell stack manufactured according to method

Abstract

The invention relates to a method for producing an electrolytic cell stack, in which a 3D printing process (hereinafter referred to as' 3D printing ') of an added and / or solidified layer is operated, said 3D printing process being repeated and periodically interrupted in order to add previously prepared workpieces (4, 5, 6), comprising a diaphragm (4), an electrode (5), an optional gasket, a bipolar pole piece (7) and / or a 3D-printed or injection-molded subunit workpiece prepared in advance and to be embedded in a stack frame (8); wherein the electrode (5), the bipolar pole piece (7) and the diaphragm (4) are arranged up and down at the center of the stack frame (8) and are aligned, and the 3D printing material is arranged to extend from the periphery of the bipolar pole piece (7) and / or from the periphery of the diaphragm (4) to the outer circumference (9) of the stack frame in the annular stack frame (8). A stack made by the method is also included.

Description

[0001] This invention relates to a method for manufacturing an electrolytic cell stack. The invention also relates to an electrolytic cell stack manufactured according to this method. Background Technology

[0002] 3D printing is a technique that adds material in small increments or as a fluid flow to an existing workpiece, where the added material is cured or hardened before the new incremental layer is added. This technology has not yet been used for pressurized electrolytic cells because it is believed that 3D printing is unlikely to provide hermetically sealed structures, such as those found in a stack of filter press-type pressurized electrolytic cells.

[0003] Therefore, one object of the present invention is to propose a method for improving electrolytic cell stacks using 3D printing technology. Summary of the Invention

[0004] The objective is achieved through an electrolytic cell stack manufacturing method, wherein a polymer material layer is added to the surface of a workpiece and cured before another polymer material layer is added, wherein the polymer material layers are added and cured sequentially at locations where physical workpiece structural components are required, while no polymer material layer is added / cured at locations where gaps are required. This process of adding and / or curing layers is referred to as 3D printing. The process is repeated and further interrupted periodically to add pre-prepared workpieces, which include diaphragms, electrodes, optional gaskets, bipolar plates, and / or pre-prepared 3D-printed or injection-molded sub-unit workpieces to be embedded in the stack. The electrodes, bipolar plates, and diaphragms are arranged vertically and aligned with each other at the center of the stack, and the 3D-printed material is arranged to extend from the periphery of the bipolar plates and / or the periphery of the diaphragms to the outer periphery of the 3D-printed workpiece in the annular stack region.

[0005] This results in greater flexibility for components (such as internal flow channels) within the annular stacked region. At the very least, connections through the manifold flow lines to the individual electrolysis chambers can be easily customized to ensure uniform flow to all chambers. Adding sensors, including electrical connectors or thermocouple elements, to specific points within the stack also becomes much easier compared to conventional stacks. This method can be used to manufacture PEM electrolyzer systems as well as alkaline systems. Furthermore, both pressurized and non-pressurized systems benefit from the improved flexibility offered by 3D printing technology when creating flow paths between individual cells within the electrolyzer.

[0006] In one embodiment of the stack manufacturing method, a polymer material is added to the upper side of the workpiece, and further, when 3D printing is temporarily stopped, a diaphragm is added to the workpiece from above, and pre-prepared polymer sub-units are added to the edge portion of the diaphragm and extended onto the 3D-printed workpiece, and a 3D-printed polymer layer is provided to weld or fused at least a portion of the intersection area between the 3D-printed workpiece and the polymer sub-units.

[0007] As a separator between half-cells, the separator used in a gas-producing electrolyzer typically comprises polymer elements. While 3D printing is not always necessary on these polymer elements, to ensure good integration of the separator into the structure manufactured according to this invention, the separator is initially placed on a 3D-printed workpiece, and a pre-prepared annular polymer element is added. This annular element covers the entire outer circumference of the separator and extends radially away from it. After arranging the annular element, a 3D printing operation is performed, or alternatively, a bonding operation is performed, to fuse the outer region of the pre-prepared annular element with the 3D-printed workpiece. Similarly, slots or holes in the workpiece can accommodate caps or tops, which are difficult to print in a 3D printing operation. Therefore, a pre-prepared cap or top-shaped element is placed to completely cover the gap, and the edge portion of the cap or top is fused with the manufactured portion. Then, 3D printing can continue, with hollow or void-like structures embedded within the printed workpiece.

[0008] In this regard, it is worth mentioning that the pre-prepared ring-shaped or cap-shaped elements can be in the form of injection-molded blanks, and then specific molded parts are added to them in the 3D printing equipment. After this final addition of material is completed, these personalized blanks are then added one by one to the stack, either by stacking them in a way that will be disassembled later, or by fusing them one by one with the personalized injection-molded blank assemblies that have already been stacked and fused together.

[0009] In one embodiment of the method, initially, pre-prepared end plates, pre-prepared insulating plates, and pre-prepared current injector plates are sequentially placed at the 3D printing location. Further, the electrolytic cell stack is 3D printed and / or the electrolytic cell stack is stacked from above onto the current injector by prefabricated elements including 3D printed parts. After the 3D printing and / or stacking operations are completed, an external packaging unit is positioned on the stack, and the pre-prepared current injector plates, insulators, and end plates are added to the build body. Subsequently, circumferentially arranged tie rods suitable for forcing the two end plates abut against each other are provided.

[0010] Encapsulation units made of fiber-reinforced resin are optional, which will also ensure that the current injectors remain isolated from each other.

[0011] It should be noted that if the package unit is made of metal, it needs to be electrically insulated from the current injectors provided at least at both ends of the stack. This insulation can take the form of a polymer ring inserted between the package and the current injector, or the package can be divided into a series of ring-shaped sub-units, each separated from the adjacent unit by a ring-shaped polymer insulating portion. In practice, the number of sub-units can be as many as the number of batteries or even half-cells in the stack, or fewer package sub-units can be used.

[0012] In one embodiment of the method, an insulating anti-diffusion material is injected to fill the annular space or void between the outer periphery of the 3D-printed battery stack and the external encapsulation unit, wherein the anti-diffusion material is added in a fluid state and is adapted to harden or solidify after injection into the annular void.

[0013] The anti-diffusion material can be an epoxy or similar curable resin, which can be added to the annular space without forming air bubbles or other voids. In one embodiment, the resin is added from below and slowly pumped into the voids through an opening in the lower portion of the encapsulation unit, or added through an annular space adapted between the current injector and the lowermost edge of the encapsulation unit, such that the injected annular space should remain filled with resin, thus also serving to electrically insulate the lower edge of the encapsulation unit from the current injector. A baking step may be required to cure the resin.

[0014] In another embodiment, the diffusion material is a rubber-type or flexible polymer, such as synthetic rubber or other two-component materials (e.g., polyurethane).

[0015] A preferred material is one that is electrically insulating, non-diffusion-resistant, and capable of transferring stress and strain caused by high pressure inside the stack to the packaging unit.

[0016] In another embodiment, the wires are electrically connected to the outer edge of the bipolar electrode, or thermocouple lead pairs are provided at any point within the half-cell, and one or more wires are embedded in the polymer material between the edge of the bipolar electrode and the outer circumference of the stack frame during the 3D printing operation, embedded in and extending through the insulating anti-diffusion material, and passing between the segments of the external encapsulation unit and / or between the encapsulation unit and the current injector, and are adapted to establish connections with measurement or recording and / or transmission devices outside the electrolytic cell stack.

[0017] One or more wires can be used for any type of measurement (e.g., temperature or voltage measurements) that can be used to diagnose the condition of a specific cell or individual cells in the stack. Furthermore, dedicated sensors within the cells or channels of the stack can be used to determine the composition of the electrolysis products, such as the residual oxygen concentration in a hydrogen product gas, or the residual hydrogen concentration in an oxygen product gas. One wire or a pair of wires can be provided for every ten or fewer bipolar electrodes, ultimately providing one or more wires and / or one or more pairs of wires for each bipolar electrode or each electrode.

[0018] The lead wires should be embedded in the 3D printing material between the measurement point and the outer periphery of the 3D printed stack material. This task is not straightforward because 3D printing is a robot-driven operation, and handling the lead wires during 3D printing is not easy. However, a retainer can be used to radially pull the lead wire or lead pair from the measurement point associated with the bipolar electrode to a radially offset point located outside the radial periphery of the 3D printed stack buildup during the printing operation.

[0019] This arrangement allows the wires to pass through the integrated package unit located between the edge of the package unit and the current injector, for example, by inserting the combined ring insulation and wire retainer into the gap at the bottom of the package unit.

[0020] Preferably, the encapsulation unit comprises at least two parts, such that a wire can pass through the space between the two parts and radially through an annular insulator inserted between the first and second encapsulation units and arranged in the midplane between the two current injectors.

[0021] In another stack manufacturing method, both the inflow manifold channel and the outflow manifold channel are shaped as manifold channels connecting each half-cell through dedicated inflow / outflow channels that directly connect each half-cell to its designated manifold channel. Each such dedicated channel is individually customized to increase according to the flow resistance along the inflow or outflow manifold channel, thereby ensuring the same flow rate in each half-cell.

[0022] In existing battery stacks, the perimeter of each half-cell is defined by an injection-molded battery frame, and dedicated flow channels are provided between the inlet manifold and outlet manifold and each half-cell within the injection-molded battery frame belonging to a specific half-cell. Since all half-cells are produced using the same injection mold, all dedicated flow channels are identical. This results in a slightly higher inflow rate for each half-cell closer to the manifold inlet and a slightly lower inflow rate for each half-cell farther from the manifold inlet, due to pressure losses caused by flow resistance along the manifold channels. When using 3D printing technology to manufacture the battery frame (e.g., in a continuous printing operation producing the entire stack frame), the flow channels from the manifold to each half-cell can be customized, making the flow through the channels and through each half-cell uniform and independent of position along the stack length axis. The length and width of individual flow channels can be customized to achieve the desired flow resistance in each individual channel. This results in a much more uniform temperature along the stack length.

[0023] In another aspect, the present invention includes an electrolytic cell stack manufactured according to the method of the invention. In this stack, inflow and outflow channels are provided for two separate electrolytes, and the inflow and outflow channels are arranged to extend along a length or radial axis, wherein the inflow and outflow channels for each electrolyte are connected to 2… n Stream distribution network, the 2 n The flow distribution network connects the input channel to the inflow distributor in each corresponding half cell and the output channel to the outflow distributor in each half cell, so that each half cell can be servable with the corresponding electrolyte.

[0024] In 2 n In the distribution network, any two cathode or anode half-cells existing in adjacent cells are directly connected at their outflow ends to the endpoint of a common manifold (hereinafter referred to as the Class A manifold). All Class A manifolds have fluid flow conduits at their midpoints, and any two such adjacent fluid flow conduits are connected at their distal ends to the endpoint of a common manifold (hereinafter referred to as the Class B manifold). All Class B manifolds have fluid flow conduits at their midpoints, and any two such adjacent conduits are connected at their distal ends to the endpoint of a common manifold (hereinafter referred to as the Class C manifold). This structure is repeated throughout Classes D, E, and F, such that each pair of inflow and outflow conduits ultimately serves two cells with inflow and outflow connections, respectively. 6= 64 half-cells. The manifolds from Class A to Class E have the same diameter at each stage; however, the diameter increases from one stage to the next. The same applies to the fluid flow conduits: the conduits connecting a particular manifold stage to the next have the same dimensions; however, the dimensions of the conduits and manifolds increase as the number of individual cells served by a particular conduit or manifold increases. The Class F manifolds connect to their respective inlet and outlet channels via fluid flow conduits at their midpoints; this is the largest flow path because it serves all 64 half-cells in the stack shown. If more cells are to be served, more stages are typically required, following the rule above: the pressure drop / boost between the electrolyte inlet / outlet of the stack and any given individual half-cell is equal in all half-cells, regardless of the half-cell's location relative to the stack's inlet or outlet connection. This is because all flow between a half-cell and its inlet or outlet channel, from the half-cell inside or outside the stack to the inlet or outlet channel, flows along manifolds and fluid flow conduits of exactly similar length and experiences similar changes in direction, thus experiencing the same amount of pressure drop.

[0025] In the above description, any manifold on the supply side or inflow side receives flow at the midpoint and directs its flow through the endpoints to a higher level; while any manifold on the half-cell receiving side or outflow side receives flow at the endpoints and directs its flow from the midpoints to a higher level. If the number of half-cells to be served is different from 2... n For integers, it is necessary to deviate from this scheme, and what is preferred in this paper is that, at the level leading to the half-cell (for outflow as level A), at least some, or preferably all, level A manifolds serve more than two half-cell connections. This would mean some individual customization of these manifolds, which can be done relatively easily to achieve a uniform voltage drop / boost between the stack inlet and each half-cell. If each level A manifold is to serve the same number of half-cells (which is preferred), a reasonable range of half-cells can be served in a given stack by having each level A manifold serve 3 to 20 half-cells. If more cells are served on the outflow side through each level A manifold, it is preferred that a similar number of cells be served on the inflow side through the last level manifold before the inflow enters the channel to reach each half-cell, such that the inflow and outflow are mirror images of each other in terms of flow distribution channels and manifolds.

[0026] On the inflow side, the inflow channel also gradually splits into increasingly smaller flow segments, and on the outflow side, the outflow from the half-cell is captured and gradually unified into a single outflow stream. Therefore, both the inflow and outflow can be designed to ensure a uniform pressure drop from the inlet to the cell and from the cell to the outlet, and to ensure uniform flow within each half-cell.

[0027] As long as the stack remains at 2 nThe flow distribution scheme ensures that all cells receive the inflow of a half-cell at the exact same pressure and receive the outflow at the exact same pressure. This uniformity of pressure drop across all half-cells in the stack guarantees that all anolyte half-cells receive the same amount of electrolyte, and the same for all catholyte half-cells, thus achieving the same temperature across all cells. This allows all cells to operate at their optimal temperature, which is highly advantageous.

[0028] In one embodiment, the inflow and outflow channels for the two separate electrolytes are arranged to extend radially from the outer periphery of the distribution plate to their respective main manifolds, which extend equally in opposite directions parallel to the stack axis from the distribution plate. The inflow and outflow channels for each electrolyte are connected to two [unclear - possibly 2] on each side of the distribution plate. n Stream distribution network, the 2 n The flow distribution network connects the inflow channel to the inflow distributor in each corresponding half cell and the outflow channel to the outflow collector in each half cell, so that each half cell can be supplied with the corresponding electrolyte.

[0029] This implementation allows the electrolyte to be supplied at the zero-potential battery when the flow distribution plate is placed at the center of the stack, and the current injector plate to be driven at potentials that are equal to and equal to the zero potential at the flow distribution plate.

[0030] In one embodiment of the invention, the electrolytic cell stack includes a conductive connection between every ten bipolar plates and each bipolar plate with at least one wire.

[0031] By electrically connecting a considerable number of bipolar electrodes to their respective measurement points and providing thermocouple temperature sensors in the relevant half-cells, the operation inside the stack can be easily monitored, events such as diaphragm burn-through can be recorded, and countermeasures can be taken, such as shutting off the current supply to the stack.

[0032] In one embodiment of the electrolytic cell stack, a cooling medium inflow and outflow manifold channel is provided in the stack, wherein the manifold cooling medium channel is connected to a cooling medium flow channel disposed in each bipolar electrode.

[0033] Providing a cooling medium to the bipolar electrodes in an electrolyzer is known in the prior art and can significantly improve stack performance because ohmic losses during electrolysis cause fluid heating in each cell, which can be offset by cooling the cell with a counter-current cooling medium that flows within channels embedded in the bipolar electrodes. In this paper, the electrolyte receives heat from the electrolysis process as it flows upward through the cell, while the heat is absorbed by the cooling medium in the bipolar electrodes, which is arranged to flow downward through channels in the bipolar electrodes. The cooling medium channels in the battery frame region can be readily provided in the same manner as the electrolyte channels, possibly relying on a manifold structure or 2 n The structure ensures that the cooling medium flows uniformly to and out of all bipolar electrodes. Countercurrent cooling can be arranged to absorb the same amount of heat generated during electrolysis, thus ensuring uniform temperature across the entire battery. This is advantageous because the efficiency of the gas evolution process increases with temperature; however, the materials used to build the battery stack, especially the separator, have an upper temperature limit above which the separator will begin to decompose. Therefore, maintaining a uniform temperature within the battery allows for a higher overall temperature because the electrolyte enters and exits the battery at the same high temperature, without being heated between the inlet and outlet.

[0034] It is worth noting that in 2 n In the flow structure, the stray current problem in the inlet and outlet manifolds is separate from the problem of ensuring uniform flow in all cells. This makes attempts to minimize stray currents much easier, and simple techniques for minimizing stray currents can be easily implemented in 2... n Implemented in the flow structure.

[0035] Patent application WO2023227462, published on November 30, 2023, discloses a 2 in an electrolytic cell. n The flow distribution network, however, is used to uniformly distribute flow across single-cell flows and process volumes. The paper mentions that a flow pulse that forces fluid to flow towards a point (where it branches into two separate but identical flows) may result in one of the two branch channels having a higher flow rate.

[0036] A first countermeasure to this potential effect, according to the invention, is to extend the inflow channel 20 and / or the outflow channel 21 all the way through the stack, providing inflow and / or outflow in equal amounts from both ends of the stack. Thus, at this stage, the fluid flow pulses may be high, with the circumferential conduits serving or receiving flow from / in both opposite directions, and the pulses caused by these flows thus balancing each other. This may work at this stage, but at higher levels, this measure is not easily implemented; preferably, longer circumferential conduits connect the stages of the axial manifold channels to each other to counteract the aforementioned problem.

[0037] It should be emphasized that the term "comprising / including / consisting of" is used in this specification to specify the presence of the described feature, integer, step or component, but does not exclude the presence or addition of one or more other features, integers, steps, components or groups thereof. Attached Figure Description

[0038] The invention will now be described in more detail with reference to the embodiments shown in the accompanying drawings. It should be emphasized that the illustrated embodiments are for illustrative purposes only and should not be used to limit the scope of the invention.

[0039] Figure 1 The 3D rendering illustrates vertical and horizontal sections passing through a 3D printed stack, which is placed vertically along its length axis.

[0040] Figure 2 This shows an enlarged portion of a single battery at its junction with the stacked 3D-printed frame portion.

[0041] Figure 3A It is a cross-sectional view along the battery stack axis, schematically showing the features within the battery frame.

[0042] Figure 3B The cross-section shown in Figure 3 also includes the cooling fluid in the half-cell frame. n Schematic diagram of the flow channel system.

[0043] Figure 4A It is an expanded projection view in which selected internal structures of the near-side stack frame are displayed as the stack scrolls relative to the paper / screen display plane.

[0044] Figure 4B An expanded view showing the central flow distribution panel is shown.

[0045] Figure 5 An enlarged view of a portion of Figure 4 is shown.

[0046] Figure 6 It was made public. Figure 5 A magnified view of a portion of the image.

[0047] Figure 7 A cross section showing a 3D representation of a prior art battery frame is shown.

[0048] Figure 8 It is an enlarged view of a cross-section through a small number of existing technology battery frames, also showing the separator and bipolar plates in the cross-section of each battery.

[0049] Figure 9 This illustrates a prior art electrolyzer battery stack.

[0050] Figure 10 Show Figure 9 The battery stack is shown, but the end flange, insulating plate, and current injector at one end are not shown.

[0051] Figure 11 yes Figure 9 A cross-sectional view in a detailed 3D projection. Detailed Implementation

[0052] It should be noted that the accompanying drawings and the following description illustrate exemplary embodiments in a simple and illustrative manner. Many specific mechanical details are not shown, as these details should be familiar to those skilled in the art, and the omission of such details would only unnecessarily complicate the description. For example, the specific materials used and the specific injection molding / 3D printing procedures are not described in detail, as it is believed that those skilled in the art can find suitable materials and processes to manufacture the stack according to the present invention based on the further information provided in this application.

[0053] To understand this invention, we first describe the state of the prior art in more detail, and then we explain this invention in conjunction with the prior art.

[0054] Detailed description of prior art To better understand the background of this invention, reference is now made to... Figures 7 to 10 Describe an example of a pressurized electrolytic cell stack in the prior art.

[0055] exist Figure 9 The image shows a 3D representation of an electrolytic cell stack. This prior art stack has two end plates 12, 12.1 (i.e., proximal end plate 12), and also has two inflow channels 20 and two outflow channels 21. The inflow channels 20 receive catholy and anolyte, respectively, while the outflow channels 21 deliver a catholy / hydrogen mixture and an anolyte / oxygen mixture, respectively. During use, the stack should be located... Figure 9 and Figure 10 The horizontal position shown, at this position, Figure 9 The indicated stack axis 29 should be horizontal. During stack construction, it is known that stack 1 is placed vertically, as shown below. Figure 1 As shown, it is located on an end plate and a current injector 14.

[0056] During use, the inflow openings of each half-cell are located at the lowest level of each half-cell, while the outflow openings are located at the highest level of each half-cell. These arrangements are maintained in the 3D-printed stack according to the invention.

[0057] At the edge of each end plate 12, 12.1, a pull rod 30 is provided and fastened by a simple nut 31 to pull the two end plates 12, 12.1 toward each other, thereby accommodating pressurized fluid and gas within the stack. Near the two end plates 12, 12.1, in addition to an insulating plate 13, distal and proximal current injectors 14, 14.1 are provided, and between the current injectors 14, 14.1, a series of individual cells (each containing two half-cells) are arranged in a row.

[0058] Each half-cell should include a housing, namely the so-called single battery frame 32, which serves four different and somewhat independent purposes: - The battery frame 32 serves as a pressure maintaining device. - Fixing the internal components of the battery, namely the separator 35, the bipolar plates 36, and the accompanying electrodes 37 and 38. - Ensure that the two different electrolytes (containing different amounts of the product gases hydrogen and oxygen, respectively) are kept separate and prevented from mixing within the stack, and, - The battery frame 32 forms an internal electrolyte and electrolyte / gas distribution network within the stack, located between the stack outlet 21 and the stack inlet 20, and is suitable for two electrolytes and electrolyte / gas mixtures.

[0059] refer to Figure 7 This explains the pressure-bearing characteristics of the battery frame. The battery frame 32 is manufactured as a separately injection-molded polymer component, and since the battery frame 32 needs to be reinforced to accommodate high pressure, the outermost portion of each battery frame is provided with a metal reinforcing ring 33. Furthermore, to prevent any leakage, O-rings 34 or similar gaskets are provided in grooves adapted to receive O-rings 34, such that even when individual battery frames 32 are forced against each other between end plates 12, 12.1, the high pressure can be maintained inside the O-rings 34.

[0060] exist Figure 8An enlarged cross-sectional view of the battery and battery frame is shown. Bipolar electrodes 36 are each electrically connected to the cathode electrode 37 on one side and to the anode electrode 38 on the opposite side, and are schematically shown together with the separator 35. Each electrode 37, 38 is generally adapted to be positioned close to the separator 35. The separator 35 serves to separate the oxygen produced at the anode electrode 38 from the hydrogen produced at the cathode electrode 37, while allowing ions and electrons to pass through the separator 35 from one electrode to the other. Thus, a process chamber or half-cell 22 is defined between the bipolar electrodes and the adjacent separator, its perimeter defined by the individual battery frame 32, separator 35, and bipolar electrodes 36. Each process chamber or half-cell 22 has an inlet at its lower portion, including an inflow distributor 27 to the associated half-cell. An outflow collector 28 from the half-cell 22 is provided at the upper portion of each process chamber 22.

[0061] like Figure 10 As shown, the inflow distributor 27 and the outflow collector 28 are each connected to a dedicated flow channel 23, provided as a recess 23 embedded within each individual battery frame 32. When this recess 23 is forced against the back of the next battery frame in the stack, the recess 23 will appear as a closed channel, with one end opening into the collector 28 or distributor 27 and the other end opening into the manifold channel. From the anode reaction chamber, the two dedicated flow channels 23 are respectively connected to the anolyte manifold channel 39 and the anolyte and oxygen manifold channel 41 inside the stack, by merging into their respective through-holes in the battery frame. Individual battery frame 32 (its front portion is shown in...) Figure 10 This includes four through-holes: one is part of the anolyte manifold channel 39 inside the stack; one opening is part of the catholyte manifold channel 40 inside the stack; one opening is part of the anolyte and oxygen manifold channel 41 inside the stack; and one opening is part of the catholyte and hydrogen manifold channel 42 inside the stack. Typically, only one identical battery frame design is used throughout the entire stack assembly, and Figure 10 The battery frame seen in the image has the same battery frame placed next to it, however, the adjacent battery frame is rotated 180 degrees about the stack length axis 24, so that, instead, the stack internal anolyte manifold channel 39 / stack internal anolyte and oxygen manifold channel 41 and the stack internal catholyte manifold channel 40 / stack internal catholyte and hydrogen manifold channel 42 are connected to the anode reaction chamber or the cathode reaction chamber through their respective dedicated flow channels 23.

[0062] Customized dedicated flow channel + inlet According to the present invention, polymer components of the battery frame are 3D printed either individually as half-cell frames and stacked, or by printing an entire ring-shaped element composed of stacked half-cell frames from the prior art to form a coherent body. This coherent body, or stacked frame, is as follows: Figure 1 As shown. Within this coherent body 8, dedicated flow channels 23, stack-internal anolyte manifold channels 39, stack-internal catholyte manifold channels 40, stack-internal anolyte and oxygen manifold channels 41, stack-internal catholyte and hydrogen manifold channels 42, as well as inflow distributor 27 and outflow collector 28 are provided as known in the art (not shown in the prior art). Figure 1 (As shown in the diagram). However, utilizing the advanced molding technology offered by 3D printing, the dedicated flow channel 23 is customized according to its position along the stack axis, such that the channel 23 closest to the inlet 20 is made slightly narrower than the channel in the battery furthest from the inlet, where the largest channel will be placed. Furthermore, the customization of the inflow dispenser to each half-cell and the outflow collector to each half-cell can also be provided based on the position of the relevant battery in the stack and the inflow and outflow specificity of the respective dispenser or collector.

[0063] Add bipolar plates and diaphragms During the 3D printing of the stacked frame, a pause is required to add the membrane 35 and the bipolar electrode 36. Typically, the bipolar electrode is fused to the cathode electrode 37 on one side and to the anode electrode 38 on the opposite side, and this assembly can be added at appropriate times during the printing operation. Preferably, a circumferential frame structure or recess 4 (such as...) should be provided in the stacked frame 8. Figure 2 (As shown by the dashed lines), this allows the outer edge portion 19 of the bipolar electrode 36 (which exceeds the diameter of the two electrodes 37, 38) to fit into the groove 4. More battery frame material should be added to cover the outer edge of the bipolar electrode 36, and this material should also be seamlessly fused to the printed layers of the stacked frame 8. A sealant may be printed onto and thus bonded to the upper side of the outer edge portion 19 of the bipolar electrode; by selecting the appropriate sealant, tight fusion with further added stacked frame layers can also be ensured. These measures ensure that gases and liquids do not leak from one side of the bipolar electrode to the other side around its outer edge. Figure 1 and Figure 2 In the diagram, the electrodes are not represented individually, but the bipolar plate 36 shown represents the entire assembly of two electrodes and the bipolar plate.

[0064] The method of adding the diaphragm is largely the same. However, the diaphragm material may be temperature sensitive, and directly printing hot melt or powder (cured by laser heating to the upper part of the diaphragm edge portion 11) may not be feasible. This problem is solved by the following method: with the diaphragm 35 already added on top of the added bipolar electrode 36 and electrode 37, 38 assembly, the sub-unit 6 (such as...) Figure 2 (As shown) is added to and covers the outer edge portion 11 of the diaphragm 35. Subunit 6 is a ring-shaped flat element whose inner diameter corresponds to the inner diameter of the stack frame 8, and whose outer diameter exceeds the diameter of the diaphragm 35. Subunits can be 3D printed or injection molded in individual locations. Subunit 6 (part of which is in…) Figure 2 (Indicated by dashed lines) includes a groove on its underside to accommodate the thickness of the diaphragm 35. Alternatively, the diaphragm may be placed in a groove provided during the 3D printing of the stack frame, and the sub-unit 6 should have a flat underside.

[0065] 3D printing and packaging unit The 3D printing process involves first providing an end plate 12 or a distal end plate 12.1 at the 3D printer location, followed by placing an insulating plate 13 on top of the end plate. A current injector plate 14 or a distal current injector 14.1 is then added on top of the insulating plate 13. Subsequently, individual cells with added separators, bipolar electrodes, and electrode assemblies are sequentially provided, as described above. Once all cells are printed, an external encapsulation unit 15 is lowered onto the printed stack frame 8, positioned on the insulating plate 13 and surrounding the stack frame 8. The external encapsulation unit 15 has an inner diameter exceeding the outer diameter of the stack frame 8, thus ensuring an annular space 17 between them. Figure 9 and Figure 10 As shown, the prior art current injector plates 14, 14.1 are provided with fishplate-shaped extensions 7, adapted to receive current supply cables for powering the stack. It should be noted that in use, a so-called current injector plate should actually function as a current collector for the DC power supply used in the electrolysis process; however, since the selected polarity of the stack is not part of this invention, both the proximal and distal plates 14, 14.1 are designated as "current injector plates," even though in reality, one plate will inject current while the opposite plate will collect current. To keep the outer encapsulation unit 15 insulated from the current injector plates 14; 14.1, especially from the fishplate-shaped extensions 7, cutouts may be provided at the ends of the encapsulation unit to ensure distance from the fishplate-shaped extensions or power terminals 7. If the outer encapsulation unit 15 is made of metal, it is particularly important to maintain a distance between its ends and any part of the current injector plates 14; 14.1. The encapsulation unit 15 may be made of fiber-reinforced materials, such as glass fiber and / or carbon fiber and / or aramid fiber-reinforced curable polymers, such as epoxy, polyester, or polyurethane. Such materials may deteriorate easily under the influence of alkaline substances; however, in the illustrated design, the external encapsulation unit 15 can remain isolated from alkaline components that may be used as the electrolyte portion in the electrolyzer. The encapsulation unit 15 may be divided into several cylindrical sub-units (not shown), with annular electrically insulating material plates between adjacent sub-units. This will further improve the electrical insulation between the power terminals 7.

[0066] A similar structure is proposed in prior art document DK178796; however, it includes further power terminals along the stack length. Even if not directly mentioned in DK178796, these terminals need to be electrically insulated from the external package unit disclosed in the document. The document does not mention the use of 3D printing technology to provide the stack frame.

[0067] An insulating and diffusion-resistant material 16 should be provided in the annular space 17 between the outer periphery of the stack frame 8 and the inner periphery of the outer packaging unit 15. The material 16 is both electrically insulating and diffusion-resistant, and should also be strong enough to transfer pressure from the outer periphery 9 of the stack frame to the outer packaging unit 15. This ensures that the stack frame should transfer its strain to the packaging unit 15 through the material 16 when internally pressurized. For this purpose, the material 16 can be selected from two-component curable resins such as epoxy, polyester, or polyurethane, which may be reinforced with glass, aramid, or carbon fiber. One advantage of these materials is that they can be molded into the annular space 17 in a liquid or semi-liquid state and remain there to cure. Preferably, the curable material is slowly pumped into the space 17 from below, so that there are no gaps between the stack frame 8 and the outer packaging unit or units 15.

[0068] To complete the stack, a second current injector is added, followed by an electrical insulation plate 13, and finally end plates 12 / 12.1. Once the two end plates 12 and 12.1 are in place, external tie rods 30 and nuts 31 are installed so that the two end plates can press against each other to accommodate the pressure inside the stack frame.

[0069] Embedding wires in a hardenable material like Figure 1 As shown, a pair of wires 18 extend along the annular space 17 between the stack frame 8 and the outer packaging unit 15, and are arranged to extend further outside the packaging unit 15, passing through a gap in the lower edge portion of the packaging unit. Such wires can also be arranged to extend upwards and across the upper edge of the packaging unit. The wires 18 preferably have an electrically insulating outer layer and can be provided in pairs, such as thermocouple pairs. With this arrangement, the temperature of various batteries or specific points within a battery can be recorded. For this purpose, the wires 18 are connected to a suitable measuring device 54. The wires 18 can also be used to carry the potential of a specific battery element (e.g., a bipolar electrode). One, two, or all batteries can be connected in this manner to allow for maximum information on the condition of each battery during electrolysis. Handling wires during 3D printing is not a straightforward task and requires some tools. However, in a preliminary approximation of a method for handling such wires, radially running V-shaped or U-shaped grooves (not shown) are allowed in the topmost layer 10 of the 3D printed stack frame during the printing process. The wires are then secured into these grooves, and subsequently, the grooves around the wires are filled using the 3D printing operation, such that each wire or wire pair is embedded in the stack frame in a leak-proof manner. This process is repeated for each battery from which one or more electrical signals need to be obtained.

[0070] Refer to Figure 3. Figure 3B , Figure 4A , Figure 4B , Figure 5 and Figure 6It describes a battery stack containing 64 batteries, resulting in 128 half-cell frames.

[0071] exist Figure 3A The diagram discloses a cross-section through a stack frame, wherein the cross-section follows a flow channel that runs circumferentially within the stack frame, and the cross-section is chosen such that any one of a plurality of axially oriented manifold channels exists within the cross-section shown, following... Figure 4A , Figure 4B , Figure 5 and Figure 6 The dashed line in the middle indicates the cross-section line S.

[0072] Expand projection and dedicated flow channel exist Figure 4A The paper discloses an unfolded projection of a battery frame stack and a current injector, wherein the stack rolls relative to a paper / screen plane, and selected stack frame structures of the proximal stack portion (closest to the paper plane) are projected onto the paper plane and schematically indicated. Note that the stack frame is circular; structures within the stack frame belonging to the distal portion of the rolling stack (opposite to the diameter of the proximal portion) are not disclosed. The rolling stack is disclosed. Figure 3A The features shown to the left of the central vertical axis do not include the cooling manifold 50, the inflow distributor 27, and the outflow collector 28.

[0073] The inflow distributor 27 and outflow collector 28 from the half-cell are only schematically indicated, but these structures typically take the shape of a manifold and are adapted to collect / distribute flow from / to a dedicated channel or recess 23, and from / to a wider area inside the half-cell. The dedicated channel 23 is implemented as a recess in the half-cell frame in prior art battery stacks; however, in 3D printing operations, the channel is implemented as an embedded channel. In prior art stacks, the dedicated channel 23 is designed to ensure that the pressure drop between the inflow channel 20 and the half-cell it feeds into is primarily achieved within the dedicated channel 23, such that the pressure drop along the length of the inflow manifold channel (the anolyte manifold channel 39 and the catholyte manifold channel 40 inside the stack) remains as small as possible, thereby ensuring equal flow into each half-cell. In 3D printed stacks, this technique can be retained, or different flow distribution schemes can be employed as disclosed below.

[0074] exist Figure 4A , Figure 5 and Figure 6 In the diagram, every four cells are numbered and indicated by a vertical dashed line J. In these figures, the separator 35 is schematically indicated by a vertical dashed line. Similarly, the bipolar electrode 36 is schematically indicated by a solid line. The electrodes are... Figure 4A , Figure 4B , Figure 5 and Figure 6Not shown in the diagram, but naturally present. The diaphragm 35 and bipolar plate 36 are... Figure 4A The lines extend from top to bottom, but to ensure better readability, they are only indicated at the top and bottom of the drawing. Dedicated flow channels 23 are schematically indicated by arrows (in...). Figure 6 (The clearest part is the individual half-cell frame). The separation between the individual half-cell frames is indicated by thin lines 44. These lines only represent the actual structure if components, partially or not using 3D printing technology, are used to manufacture the stacked frame 8.

[0075] refer to Figure 4A It is also noted that the flow distribution network 26 between the individual half-cells and the outflow channel 21 is indicated in the upper left corner. Although the inflow channel 20 is shown, the individual paths from the inflow channel 20 to each half-cell are not shown because these paths reflect... Figure 4A The channel distribution network 26 between the single half-cell and the outflow channel 21 shown in the upper left.

[0076] Figure 4A , Figure 4B , Figure 5 and Figure 6 The dashed line S in the middle indicates that it passes through Figure 3A The cross-sections of different levels AH of the flow channels formed in the battery frame are shown.

[0077] As mentioned above, Figure 3B The cooling channel 50 in the middle is not in Figure 4A , Figure 4B , Figure 5 and Figure 6 The text indicates that because cooling flow is an optional feature, and Figure 4A , Figure 4B , Figure 5 and Figure 6 The representation would interfere with the illustration of the inflow / outflow channel system. Furthermore, the reverse inflow and outflow schemes, as well as the subsequent sections A to G, are not shown in any unfolded projection, but are only indicated in Figure 3.

[0078] exist Figure 4B In the diagram, dotted portion 21 indicates the flow of anolyte and oxygen out of the stack in the anolyte and oxygen manifold channel 41, and dotted portion 20 indicates the flow of anolyte into the stack. Therefore, the diagonal stripes indicate the anolyte / oxygen flow originating from the anolyte half-cell in the stack, which merges with dotted portion 21 to flow radially out of the stack through dotted channel 21. Similarly, the anolyte flow into the stack is indicated by dotted portion 20, and then merges with the diagonal stripe channel, flowing through 2... n The channel enters a single half-cell.

[0079] Detailed description of balanced flow channels In these diagrams, every other half-cell houses the cathode electrode, while the other half-cell houses the anode electrode, and the respective anolyte and catholyte connections should be connected to each half-cell via exposed network 26. Assuming the first half-cell in the stack is named 1A and the second half-cell is named 1B, then half-cell 1A is located next to current injector 14, as shown... Figure 6 The following pair of half-cells will be referred to as 2A and 2B, respectively. Assume that half-cells 1A and 2A are anolyte half-cells with an anode, which require an anolyte inflow supplied by the anolyte manifold channel 39 inside the stack, and connected to the anolyte and oxygen manifold channel 41 to deliver the anolyte and oxygen half-cell output out of stack 1.

[0080] Any two cathode or anode half-cells of this type located in adjacent cells are directly connected to the endpoints of a common manifold, hereinafter referred to as Class A manifold 45. Class A manifold 45 in... Figure 6 The middle section is the clearest example; each of them is very short, spanning three half-cells, collecting output from only two half-cells, and receiving this as input at its respective endpoint. In the disclosed example of the invention, all Class A manifolds 45 are provided along a single, identical axis parallel to the stack length axis. Each Class A manifold is also connected at its midpoint to a fluid flow conduit, referred to as a Class B conduit 46 (see [link to invention]). Figure 5 and Figure 6 The Class B catheter 46 is also... Figure 3A As can be seen, it is circumferential relative to the battery frame, unlike all the axially extending manifolds.

[0081] Any two adjacent Class B fluid flow conduits 46 are connected at their distal ends to the endpoint of a common manifold, hereinafter referred to as Class B manifold 47. All Class B manifolds 47 have a fluid flow conduit at their midpoint, referred to as Class C conduit 48, and any two such adjacent conduits are connected at their distal ends to the endpoint of a common manifold, hereinafter referred to as Class C manifold 49. This configuration is repeated throughout Classes D, E, and F, such that a pair of inflow and outflow conduits 20, 21 ultimately serve Class 2. 6 = 64 half-cells, for example, 64 anolyte half-cells, while another pair of inflow and outflow 20, 21 serve 2 6 There are 64 half-cells, which are cathodic liquid half-cells.

[0082] The manifolds from Class A to Class E have the same diameter at each individual stage; however, the diameter increases as one moves from one stage to the next, away from the individual half-cell and toward the outflow channel 21, or from the individual cell toward the inflow channel 21. The same applies to the fluid flow conduits: the conduits connecting a particular manifold stage to the next stage are all of the same size; however, the conduits closer to the individual half-cell in terms of flow are smaller than those closer to the inflow / outflow channels 21, 20. The Class F manifold connects to its respective inflow and outflow channels 20, 21 at its midpoint via fluid flow conduits. If more cells are to be served, typically more stages are needed, and by following the rules above, the pressure drop / boost between the electrolyte at the inlet / outlet of the stack and any given individual half-cell will be equal in all half-cells.

[0083] The above description refers to the output section of the battery frame, but the shape of the inflow channel on the lower left side is an exact mirror image of the outflow path, so it will not be described in detail here.

[0084] Another example of an inflow path is in Figure 3B The cross-section is shown, where the cross-section follows and thus shows all manifold channels. In the inflow section, fluid flows from the larger channel or manifold to the smaller channel, splitting the input flow into two equal flows each time. In the output section, the flow from a single half-cell is collected, with the flow moving from the smaller channel toward the larger channel, always merging two flows of the same level into a single larger flow of the adjacent level.

[0085] Figure 3B The cross-section shown through the stack frame follows the inflow and outflow conduits and the accompanying manifolds, also on the right side of the figure, where orifices for the corresponding manifold channels at each level are present. Furthermore, in Figure 3B In the middle, the larger inflow channels 21 are arranged closer to the individual half-cell dispensers or collectors, while very small manifolds serving only two cells are located further away from the collectors or dispensers within the cells. This makes the dedicated flow path 23 leading to / from each individual half-cell long and winding. [Stage indicator and...] Figure 3A The same applies to Class A manifolds, which are closest to the individual half-cells in terms of flow, while Class G manifolds represent manifolds closest to the inflow / outflow channels 20 and 21.

[0086] Note that in Figure 3B In the middle, the fluid flow conduits between the larger manifold channels are shown Figure 3B On the right side of the cross-section, this reflects the fact that for larger manifold channels, the interconnecting fluid flow conduits running circumferentially need to extend beyond the thickness of a half-cell frame to accommodate the flow. Fluid flow channels between manifold channels serving fewer half-cells only need to extend the width of a half-cell frame or less, and therefore only... Figure 3B The left side of the cross-section is shown. This also applies to cooling channels.

[0087] Each catholy half-cell should be located next to the anolyte half-cell; examples of catholy half-cells are 1B and 2B. When the catholyte half-cell frame is rotated as described above... Figure 3A The holes shown on the upper right and lower right sides of the battery stack cross-section should serve to complete each manifold channel 45, 47, 49 and further to the Class G manifold, as well as the Class H manifold, as previously stated. Figure 3A The corresponding manifold shown in the upper left corner.

[0088] exist Figure 4A and Figure 4B In the diagram, batteries 52-64 are not shown, and for these batteries, the C, B, and A grade manifolds and conduits are not fully depicted in more detail because they only represent repetitions of the elements already shown.

[0089] Cooling flow, stack length exist Figure 3A and Figure 3B The diagram schematically illustrates an internal cooling channel 50 within the stack, and an internal cooling channel 51 suitable for extending within the bipolar electrode. Note that the bipolar electrode may require additional thickness to accommodate the cooling channels, resulting in a similar increase in the thickness of the individual half-cell frame, which in turn increases the thickness of the internal cooling channel 50 within the stack. n Allocate space for the cooling network, and Figure 3B The image shows cooling channels and electrolyte channels coexisting near the inflow and outflow of the half-cell. Note that if cooling is to be optimized to ensure uniform distribution of cooling fluid along the stack length, 2... n Distribution network. Therefore, in Figure 3B In the diagram, channel 50 is exposed as a plurality of interconnected channels, positioned somewhat separately from the electrolyte channels. Axial and circumferential cooling channels are exposed in the cross-sectional view, requiring the selection of the cross-sectional view to follow the actual placement trajectory of the circumferential channels within the stack frame. This is particularly relevant for... Figure 3B ,2 n The schematic diagram of the electrolyte distribution channels shows that the smallest manifold channel 45 is furthest from its respective inflow distributor 27 or outflow collector. This makes the dedicated flow channel 23, serving only one half-cell, very long, which, while sacrificing in terms of flow resistance and increased electrolyte pump requirements, may be beneficial in some applications. However, using 2... n The considerable number of design options available for the flow distribution network is itself an advantage. In existing technologies, cooling within the bipolar electrode is not extensively utilized because the increased thickness of each half-cell also increases the challenge of ensuring equal inflow and outflow of electrolyte for all cells in the stack. However, using 2... nDistribution networks will significantly minimize this challenge and allow for the construction of longer stacks with more cells. Another benefit of a high number of cells is the ability to provide a higher potential difference between current injectors, which allows for more efficient and simpler converter construction for AC-to-DC converters commonly used in water electrolysis.

[0090] The preferred cooling medium comprises clean water, preferably also clean water used as the supply water for the relevant electrolytic cell. This provision will allow cross-contamination between the cooling flow and the electrolyte flow in the stack without causing any serious safety hazards. However, the cooling water should not be over-contaminated with the electrolyte, as this would cause stray currents to also propagate along the cooling channels due to the fact that the cooling water in each bipolar electrode is exposed to the potential in that plate. It is possible that the cooling flow is maintained at a pressure level exceeding that in the electrolyte so that any possible leaks can propagate from the cooling water to the electrolyte fluid. Figure 3B 2 n Cooling channels and 2 n Cross-sectional views of the electrolyte inflow and outflow channels are not shown in the image. Figure 4A The repetition in the rolling projection is primarily because it would be difficult to display the projections of cooling channels and electrolyte channels together on the same drawing. Note that the cooling flow operating in each half-cell plane needs to be alternately directed to the foremost or last plane of a given half-cell, depending on whether the half-cell is an anolyte or catholyte half-cell element. This stems from the fact that bipolar electrodes exist only every other half-cell, while cooling channels exist in all half-cells, and it is preferable to utilize the cooling channels as much as possible. n Distribution network. Each half-cell may have a small, insertable or movable component at each cooling channel inflow / outflow to / from the cooling channel in the bipolar electrode to accommodate this flow variation within the alternating half-cell. In practice, the bipolar electrode will supply cooling medium from both of the two cell frames it abuts against at its edge portions, assuming the structure is built on separately stacked half-cell frames. Flow control is embedded within the 3D-printed structure in the 3D-printed stack.

[0091] 2 n The flow in a distribution network may not be perfectly symmetrical in terms of flow distribution at the split / connection points. To achieve symmetrical flow distribution, it is advisable to use flow guides along manifold channels or between different adjacent manifold levels. Such flow guides can also prevent the formation of unwanted eddies within the flowing liquid.

[0092] In the publicly available 2 n In the network distribution example, when using an injection-molded half-cell frame, the O-ring gasket 34 and metal reinforcing ring typically provided at each half-cell are not shown. However, these components are naturally mounted in their respective locations.

[0093] Stack length, number of batteries and voltage exist Figure 4A In this configuration, current injector plates 14 and 14.1 are at +½V and -½V, respectively, where V represents the voltage rating. This results in a total exposed stack voltage of V, where the center cell, here cell number 32, is at zero potential. Inflow channel 21 and outflow channel 20 extend from the +V current injector plate 14 directly to the center cell 32; therefore, an insulating bushing 52 should be provided around each electrolyte channel passing through this current injector plate to ensure no current connection between the electrolyte and the current injector plate 14.

[0094] As is known in the prior art, the distribution plate 53 provides flow at the electrically neutral cell, and in this current example, between cells numbered 32 and 33 in the electrolytic cell stack, allowing radial inflow and outflow into and out of the stack to supply its two halves, i.e., cells numbered 1-32 on one side of the distribution plate and cells numbered 33-64 on the opposite side. This arrangement in Figure 4B The diagram is schematically disclosed. This allows flow into and out of the stack to enter at an uncharged point. This has several advantages and eliminates the need for a long inflow path from the high-charge current injector to the zero-potential cell.

[0095] With the addition of a distribution stage, a total of 128 cells in the stack is possible, with radial or axial inflow channels 20, 21. Stacks with 256, 512, or even 1024 cells are conceivable, through two channels for electrolyte and cooling flow. n Further allocation levels are added to the allocation network.

[0096] If it cannot be represented as 2 n A power-number of batteries can provide a stack with the number of batteries according to the following formula: The number of batteries in the stack = (2+a)(2+b)(2+c)……(2+n); Where integers a, b, c ... n ∈ [0,1] Furthermore, a, b, c ... n each represent a manifold level.

[0097] This allows for a much larger number of different batteries in the stack without significantly deviating from the 2x2 distribution network. n The original formula. Any manifold can easily include only 3 manifolds without violating the idea of ​​uniform flow in the 3 ducts exiting each such 3-way manifold, even if special provisions are required to ensure uniform outflow / inflow at the 3 openings of such a manifold.

[0098] 2 n Distribution Network The 2 shown nThe complex nature of distribution networks is well-suited for 3D printing operations; however, this can be accomplished through other means, such as injection molding a half-cell frame into a blank without any flow distribution structures, and then machining these structures into each half-cell frame in a CNC machining center after the half-cell frame operation. Instead of machining the complete half-cell frame, smaller parts can be machined and then assembled into the injection-molded half-cell frame blank, where the openings for individually machining the smaller parts are part of the injection molding tool. It should be understood that whenever a part undergoes a process where its final shape is reached by removing material, such as in a machining center, there is always an option to reach the same final shape by adding material to the workpiece, such as through 3D printing. Both operations can likely be utilized to reach the final shape of the half-cell frame more quickly. Operations such as adding spacer material to the battery frame are particularly effective in 3D printing.

[0099] Half-cell variant injection molding The half-cell frame, as an injection-molded part, is essentially a flat plastic ring with one or more through-holes, forming a manifold with stacked axes aligned. For the manifold through-holes, in some cases adjacent stacked circumferential flow guides are arranged; these are also through-holes, however not necessarily circular, and are always connected to through-holes at each end. To achieve the above-mentioned 2 for electrolyte and cooling medium... n In principle, each half-cell in a given stack requires an injection molding tool for the flow structure. However, each through-hole, whether a manifold or a stacked circumferential flow conduit, can be provided in the flat part by a movable core, which either retracts, leaving no hole or flow conduit in the workpiece (half-cell frame), or extends to or against the relative inner cavity wall or into the cavity a certain distance to form a space or void constituting a flow conduit or through-hole. Such cores can be made without draft angles, taking into account the thinness of the cell frame and further considering the possibility of retracting the core before the workpiece is completely demolded from the cavity. Allowing such cores, individually controlled by the injection molding machine, allows one and only one injection molding tool to be used to produce each individual half-cell frame described in the stack, including the cooling flow conduit. Even, at least in theory, it is possible to mold individual half-cell frames in the stack sequentially from one end to the other according to their numbering in the stack. Such sequential molding of individual and dissimilar parts is not common and requires the injection molding machine to reprogram certain parts of its process, such as the plasticizing volume and injection volume, and the timing of the point at which the switch between injection and holding pressure is initiated before each molding cycle. This is not a standard procedure for most injection molding machines; however, such changes in operating parameters before each individual molding cycle can be achieved through software variations in modern injection molding machines.

[0100] It should be noted that the accompanying drawings and the above description illustrate exemplary embodiments in a simple and illustrative manner. Many specific mechanical details are not shown, as those skilled in the art should be familiar with such details, and the unshown details would only unnecessarily complicate this description.

[0101] Parts list 1 Electrolytic cell stack 2 Physical workpiece structural components 3 gaps 43D printed grooves 5 electrodes 6 3D printed and / or injection molded sub-units 7. Fish-plate-shaped extension or power terminal of the current injector board 8 stack frames 9. Outer circumference of the stack frame 10. Upper side of the workpiece 11. Diaphragm edge portion 12 Proximal endplate 12.1 Distal endplate 13 Insulation Board 14 Proximal Current Injector 14.1 Distal Current Injector 15 external packaging units 16 Insulating and Anti-diffusion Materials 17. Circular Space 18 wires 19 Bipolar electrode edge portion 20 Inflow Channels 21 outflow channels 22 half-cell 23. Dedicated flow channels or grooves 24 stack length axis 25 Central Plane 262 n Stream distribution network 27 to half-cell inflow distributor 28 outflow collectors from half-cells 29 stack axis 30 pull rod 31 nuts 32 individual battery frames 33 Metal Reinforced Ring 34 O-ring 35 diaphragm 36 Bipolar Plates 37 Cathode Electrode 38 Anode Electrode 39. Internal Anode Liquid Manifold Channel of Stack 40. Internal cathode liquid manifold channel of the stack 41. Internal anolyte and oxygen manifold channels of the stack 42. Internal cathode liquid and hydrogen manifold channels of the stack 43. Central vertical axis 44 dividing lines between individual half-cells 45A Class Manifold 46B grade catheter 47B Class Manifold 48C grade catheter 49C Class Manifold 50 stack internal cooling channels 51 Battery Internal Cooling Channel 51 Electrical insulation bushing 52 Electrical insulation bushing 53 Stream Distribution Board 54 Measuring Equipment / Measuring Instruments A-level expansion / Grade A B-level expansion / Grade B C-level expansion / C grade D unfolding / D grade E-deployment / E-level F unfolding / F level G-level / G-grade H-expansion / H-level The vertical dashed line J indicates the battery number. The dashed S-line indicates the cross-sections at different levels passing through the flow channels formed in the battery frame.

Claims

1. A method for manufacturing an electrolytic cell stack (1), wherein, A polymer material layer is added to the surface of the workpiece and cured before the next polymer material layer is added, wherein the polymer material is added and cured at the physical workpiece structural parts (2) where physical workpiece structure components (2) are required, while no polymer material is added / cured at the gaps (3) where polymer material is required. This process of adding and / or curing layers is referred to as 3D printing. This process is repeated and periodically interrupted to add pre-prepared workpieces (4, 5, 6), which include a diaphragm (4), an electrode (5), an optional gasket, a bipolar electrode (7) and / or a pre-prepared 3D printed or injection molded sub-unit workpiece to be embedded in a stack frame (8); wherein the electrode (5), the bipolar electrode (7) and the diaphragm (4) are arranged vertically and aligned with each other at the center of the stack frame (8), and the 3D printed material is arranged in the annular stack frame (8) extending from the periphery of the bipolar electrode (7) and / or from the periphery of the diaphragm (4) to the outer circumference (9) of the stack frame.

2. The method for manufacturing the electrolytic cell stack (1) according to claim 1, characterized in that, Polymer material is added to the upper side (10) of the workpiece, and a diaphragm (4) is added from above to the workpiece while 3D printing is temporarily stopped. A pre-prepared polymer sub-unit (6) is added to the edge portion (11) of the diaphragm (4) and extended to the 3D printed workpiece. A 3D printed layer of polymer is provided to the 3D printed workpiece and the polymer sub-unit (6) to fuse them together.

3. The method for manufacturing the electrolytic cell stack (1) according to claim 2, characterized in that, First, the pre-prepared end flange (12), the pre-prepared insulating plate (13), and the pre-prepared current injector (14) are placed sequentially at the 3D printing position. The electrolytic cell stack (1) is then 3D printed and assembled from above onto the current injector (14). After the 3D printing operation, the outer packaging unit (15) is lowered onto the stack (1), and the pre-prepared current injector (14), insulator, and end flange are added to the build body. Subsequently, circumferentially arranged tie rods suitable for forcing the two end flanges to abut against each other are provided.

4. The method for manufacturing an electrolytic cell stack according to claim 3, characterized in that, An electrically insulating anti-diffusion material (16) is injected to fill the annular gap (17) between the 3D printed battery stack (1) and the external encapsulation unit (15), wherein the electrically insulating anti-diffusion material is added in a fluid state and is adapted to harden or cure after being injected into the gap or space (17) between the stack (1) and the encapsulation unit (15) or multiple encapsulation units (15).

5. The method for manufacturing an electrolytic cell stack according to claim 4, characterized in that, The wire (18) is electrically connected to the outer edge (19) of the bipolar plate (7) and / or provides a thermocouple lead pair (18) at a point within the half-cell, wherein, during the 3D printing operation, the wire and / or thermocouple lead (18) is embedded in the polymer material between the edge (19) of the bipolar plate and the outer circumference (9) of the stack frame, and is embedded and extends through the insulating anti-diffusion material (16), and through the segments of the external encapsulation unit (15) and / or through the encapsulation unit (15) and the current injector (14; 14.1), and is adapted to establish a connection with a measuring device outside the electrolytic cell stack (1).

6. The method for manufacturing an electrolytic cell stack according to any one of claims 1-5, characterized in that, Both the inflow channel (20) and the outflow channel (21) are shaped as manifold channels connecting their respective half-cells (22) through dedicated flow channels (23), which directly connect their respective half-cells (22) to the manifold channels (21), wherein each dedicated flow channel (23) is customized to increase the flow resistance along the inflow channel (21) to ensure the same flow rate in each half-cell (22).

7. The electrolytic cell stack manufactured according to any one of claims 1-5, characterized in that, For each of the two individual electrolytes, an inflow channel (20) and an outflow channel (21) are provided, arranged to extend along the stack length or the stack radial axis, wherein the inflow channel and outflow channel (20, 21) of each electrolyte are connected to 2 n Stream distribution network (26), the 2 n The flow distribution network (26) connects the inflow channel (20) and the inflow distributor (27) in each corresponding half cell, and connects the outflow channel (21) and the outflow collector (28) in each half cell, wherein each half cell (22) is capable of supplying the corresponding electrolyte and has an outflow capacity.

8. The electrolytic cell stack manufactured according to any one of claims 1-5, characterized in that, The inflow channels (20) and outflow channels (21) for the two separate electrolytes are arranged to extend radially from the outer periphery of the flow distribution plate (53) to their respective main manifolds, which extend equally in opposite directions from the flow distribution plate (53), wherein the inflow channels and outflow channels (20, 21) for each electrolyte are connected to 2 n Stream distribution network (26), the 2 n The flow distribution network connects the inflow channel (20) and the inflow distributor (27) in each corresponding half cell, and connects the outflow channel (21) and the outflow collector (28) in each half cell, wherein each half cell (22) is able to supply the corresponding electrolyte.

9. The electrolytic cell stack manufactured according to any one of claims 7-8, characterized in that, Each of the ten bipolar plates includes a conductive connection with at least one wire (18) between each bipolar plate (7).

10. The electrolytic cell stack according to any one of claims 7-9, characterized in that, Cooling medium inflow and outflow manifold channels (50) are provided in the stack and connected to cooling medium flow channels (51) provided in each bipolar electrode.

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