Adhesive-Fixed Electrolysis Module Assembly for Zero-Gap Stacking
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Solution Overview
Problem
Conventional alkaline water electrolysis modules face challenges in assembly complexity, increased size and volume, and reduced efficiency due to inconsistent stack components, as well as difficulties in repair and replacement, particularly in single-cell stacking type modules, while bolt-pressed stacking type modules suffer from increased parts and performance issues with incorrect assembly.
Innovation Solution
An adhesive-fixed electrolysis module that assembles stacks by adhering bipolar plates and cell frames using an adhesive, combined with a physical fastening mechanism, ensuring a zero-gap configuration and secure fastening without welding or bolting, allowing for flexible capacity adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-cell stacking type electrolysis module is used, then product stability and technological prowess are secured, but the size and volume increase and the number of parts increases
Solution Approach 1:
The patent divides the electrolysis system into modular single stacks that can be independently assembled and disassembled. Each single stack contains essential components (separator, bipolar plate, gasket, diffusion layer, electrode, cell frame) that can be stacked to form the complete electrolysis module, reducing overall volume while maintaining product stability through standardized modular units.
Solution Approach 2:
The patent implements a nested structure where multiple single stacks are stacked within a containing structure to form the complete electrolysis module. The bipolar plates and cell frames are nested together with gaskets and diffusion layers in between, creating a compact configuration that reduces volume while maintaining all necessary functional components.
2Reliability
If single-cell stacking type electrolysis module is used, then product stability is secured, but the number of parts increases
Solution Approach 1:
The patent merges multiple functional components into integrated assemblies. The bipolar plate and cell frame are combined with gaskets and diffusion layers to form complete single stacks, reducing the number of separate parts that need to be handled individually. This merging approach maintains product stability through consistent assembly while reducing overall part count.
Solution Approach 2:
The patent designs universal single stack modules that can be used in various configurations to create different electrolysis module capacities. Each single stack contains all necessary components (separator, bipolar plate, gasket, diffusion layer, electrode, cell frame) to function independently, allowing the same modular unit to serve multiple purposes and reducing the need for specialized parts.
3Productivity
If bolt-pressed stacking type electrolysis module is used, then excellent performance is secured by simplifying gas and liquid channels, but the number of parts increases
Solution Approach 1:
The patent segments the electrolysis system into standardized single stack modules that maintain the simplified gas and liquid channel design of bolt-pressed stacking while reducing the number of parts through modular assembly. Each single stack is a self-contained unit that can be stacked to achieve the desired capacity without requiring additional specialized parts for each stack.
Solution Approach 2:
The patent creates universal single stack modules that incorporate the simplified channel design into a multi-functional unit. Each module serves multiple functions (gas flow, liquid flow, electrical connection, sealing) through integrated components, reducing the number of separate parts needed while maintaining the performance benefits of simplified channels.
4Productivity
If bolt-pressed stacking type electrolysis module is used, then excellent performance is secured, but replacement and repair are difficult
Solution Approach 1:
The patent divides the system into separable single stack modules that can be independently removed and replaced. This segmentation allows damaged modules to be quickly swapped out without disassembling the entire electrolysis system, maintaining the simplified channel design performance while dramatically improving ease of repair and replacement.
Solution Approach 2:
The patent designs single stack modules with pre-assembled components (bipolar plate, cell frame, gaskets, diffusion layers, electrodes) that are prepared in advance as complete units. This preliminary assembly allows for quick replacement of entire modules rather than troubleshooting and repairing individual components, improving ease of repair while maintaining the performance benefits of the simplified design.
5Ease of manufacture
If adhesive fixing is used to assemble stacks, then assembly is simplified and internal resistance is reduced, but assembly precision must be maintained
Solution Approach 1:
The patent replaces traditional mechanical fastening methods (bolts, welds) with adhesive bonding to assemble the single stack modules. This substitution simplifies the assembly process by eliminating complex mechanical fastening operations while maintaining precise alignment through the adhesive bonding surface, reducing internal resistance and improving electrical contact between components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies assembly, reduces internal resistance, and enhances operational efficiency by fixing components accurately without gaps, facilitating easier repairs and flexible capacity adjustments.
Implementation Method 1
fixing a bipolar plate and a cell frame with an adhesive
Implementation Method 2
Water electrolysis is a technology for producing high-purity (99.999%) green hydrogen by electrolyzing water
Data Source
AI summary
Provided is an adhesive-fixed electrolysis module comprising a single stack, the single stack having a separator, a pair of bipolar plates, a pair of gaskets, a pair of diffusion layers, a pair of electrodes, and a cell frame, wherein the bipolar plates, the gaskets, the diffusion layers, and the electrodes are sequentially arranged on the cathode and anode sides, respectively, with respect to the separator, forming a symmetrical structure, wherein the separator, the bipolar plates, the gaskets, the diffusion layers, and the electrodes are stacked in a zero-gap manner within the cell frame, and wherein the bipolar plates are adhered and fixed to the cell frame using an adhesive, thereby simplifying product assembly and reducing assembly costs compared to a single stack fixing method using welding, riveting, bolting, etc. between conventional parts.