3D Regular Metal Skeleton Electrode for Low-Pressure Gas Discharge
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Solution Overview
Problem
Existing porous metal components used in electrodes and current collectors face challenges such as random pore arrangements leading to inefficient gas discharge, high pressure loss, and difficulty in controlling pore size and porosity, which affect electrolysis efficiency and fluid flow.
Innovation Solution
A metal member with a three-dimensional regular framework structure having a porosity range of 50% to 95% and pore diameters between 50 µm and 1,500 µm, with alternating pore and framework rows in a laminated structure, allowing for stable fluid flow and reduced pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a porous metal component with random pore structure is used, then the filling density of active material can be maximized, but the gas discharge efficiency decreases and electrolysis efficiency is reduced
Solution Approach 1:
The patent divides the porous structure into regularly arranged pores and frameworks instead of random distribution. The pores are segmented into specific size ranges (50-1500 µm) and arranged in periodic patterns, enabling both high active material filling and efficient gas discharge pathways.
Solution Approach 2:
The patent applies different pore size characteristics at different locations within the electrode. The pore diameter varies from 50-1500 µm to optimize local functions: smaller pores for active material filling and larger pores for gas discharge, creating spatially differentiated functionality within the same structure.
2Area of stationary object
If a highly porous metal component is used to increase three-phase interface area, then the contact area with catalyst increases, but the structural strength decreases and pressure loss increases
Solution Approach 1:
The patent optimizes the porosity parameter to a specific range (50-95%) rather than using maximum porosity. This parameter optimization balances the three-phase interface area with structural strength, ensuring the electrode can withstand operational pressures while maintaining sufficient catalytic contact area.
Solution Approach 2:
The patent creates a composite structure combining metal frameworks with porous characteristics. The regular framework provides structural strength while the porous regions provide three-phase interface area, achieving a balance between mechanical integrity and catalytic functionality.
3Area of stationary object
If a porous metal component with small pore diameter is used, then the contact area with catalyst increases, but the pressure loss for fluid flow increases and gas discharge becomes difficult
Solution Approach 1:
The patent transitions from considering only pore diameter (one dimension) to incorporating pore arrangement in multiple dimensions. The regular periodic arrangement of pores in three-dimensional space creates efficient flow pathways that reduce pressure loss while maintaining large total contact area through optimized spatial distribution.
Solution Approach 2:
The patent implements a periodic arrangement of pores and frameworks in regular intervals. This periodic structure creates consistent flow channels that facilitate gas discharge while maintaining catalyst contact area, preventing the pressure loss associated with random or irregular pore distributions.
4Ease of manufacture
If a porous metal component with irregular pore arrangement is used, then the manufacturing process is simpler, but the fluid flow efficiency decreases and pressure loss increases
Solution Approach 1:
The patent incorporates flow channel formation into the initial electrode manufacturing process rather than adding it as a separate step. The porous structure is formed with predetermined regular pore arrangements during electrode fabrication, simultaneously achieving manufacturing simplicity and fluid flow efficiency without requiring subsequent complex modifications.
Data Source
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AI summary
This metal member is a metal member having a three-dimensional regular framework structure with a porosity in a range of 50% or more and 95% or less, wherein the three-dimensional regular framework structure has a framework and a plurality of pores extending in a first direction, in a cross section perpendicular to the first direction, pore rows in which the pores and the frameworks are alternately arranged are periodically laminated to form a lamination structure. In addition, the electrode has a well-shaped sheet layer having a plurality of through-holes in a thickness direction, the porosity of the well-shaped sheet layer is in a range of 20% or more and 70% or less, and the thickness of the well-shaped sheet layer is in a range of 10 µm or more and 500 µm or less.