Bifacial Sealed Gas Diffusion Electrode for Stable Triple-Phase Boundaries

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Solution Overview

Problem

Existing metal-air batteries are not suitable for large-scale energy storage due to mechanical cell architecture challenges, particularly in maintaining triple-phase boundaries for oxygen reduction and evolution reactions, which are crucial for long and ultra-long duration energy storage.

Innovation Solution

Development of bifacial sealed gas diffusion electrodes (GDE) assemblies with submerged oxygen reduction reaction (ORR) electrodes, utilizing a laminate structure and sealing processes to maintain triple-phase boundaries, allowing for efficient oxygen reaction and extended energy storage capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional metal-air battery architectures are used, then small-scale storage is achieved, but large-scale energy storage capability deteriorates

Engineering Contradiction:

Improveenergy storage capacityVSAvoidmechanical cell architecture

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The battery system is divided into modular units, each containing a gas diffusion electrode assembly with sealed triple-phase boundaries. These modular units can be scaled by adding more modules in parallel, enabling large-scale energy storage while maintaining the simplicity of individual cell architectures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from traditional planar electrode configurations to three-dimensional sealed gas diffusion electrode structures with integrated flow fields. This dimensional change allows for improved mass transport and reaction efficiency within a compact volume, enabling scalable energy storage capacity without proportionally increasing mechanical complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If triple-phase boundaries are maintained for oxygen reactions, then reaction efficiency is improved, but mechanical stability deteriorates

Engineering Contradiction:

Improveoxygen reaction efficiencyVSAvoidmechanical stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The gas diffusion electrode employs a composite structure combining hydrophobic porous materials (for gas transport) with hydrophilic catalyst layers (for oxygen reactions), all encapsulated in a mechanically robust sealed housing. This composite architecture maintains the triple-phase boundary functionality while the external seal provides mechanical stability and prevents electrolyte leakage.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The sealed housing structure is designed with pre-integrated sealing elements and reinforcement features that compensate for mechanical stresses before they occur. The rigid outer shell protects the delicate triple-phase boundary interface from mechanical degradation, maintaining both reaction efficiency and structural integrity during operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If sealed gas diffusion electrodes are used, then leakage risk is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveleakage resistanceVSAvoidsealing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing function is merged with the electrode structure itself by integrating the sealant layer directly onto the gas diffusion electrode during manufacturing. This combined structure eliminates separate sealing components and assembly steps, reducing manufacturing complexity while maintaining reliable leakage prevention through the integrated sealed boundary.

Inventive Principle:

Principle #5Merging (Combining)

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

The bifacial sealed GDE assemblies enhance the efficiency and durability of metal-air batteries, enabling long and ultra-long duration energy storage by maintaining stable triple-phase boundaries and reducing leakage risks, thus supporting grid-scale energy storage applications.

Implementation Method 1

submerged Oxygen Reduction Reaction (ORR) electrodes

Methodology Applied

Scientific EffectOxygen reduction reaction (ORR): Redox Reactions

Implementation Method 2

bifacial sealed gas diffusion electrodes (GDE) assemblies

Methodology Applied

Scientific EffectGas diffusion: Diffusion

Data Source

PatentUS12567625B2Bifacial sealed gas diffusion electrode

Publication Date: 2026.03.03 FORM ENERGY INC

AI summary

Systems and methods of the various embodiments may provide bifacial sealed gas diffusion electrode (GDE) assemblies. In some embodiments, a bifacial sealed gas diffusion electrode (GDE) assembly includes active electrode layers on two opposing sides of the assembly. Various embodiments may provide architecture and/or sealing methods for GDE assemblies. In various embodiments, the GDE assemblies may be for use in devices. In various embodiments, the devices may be primary or secondary batteries. In various embodiments, these devices may be useful for energy storage. For example, bifacial sealed GDE assemblies of the various embodiments may form cathode electrodes (sometimes called air electrodes) of a battery, such as a metal-air battery.