Carbon Electrode Frame with Cut-Outs for Large Surface Area
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Solution Overview
Problem
Current carbon-based electrodes with large geometric dimensions are challenging to produce due to brittleness and mechanical weakness, limiting their size and efficiency in electrochemical reactors, and existing solutions are either incompatible or energy-intensive.
Innovation Solution
A carbon-based electrode design featuring a conductive frame with cut-outs for sub-electrodes, ensuring mechanical robustness and uniform current distribution, allowing for larger surface areas without the need for adapting manufacturing processes, and maintaining accessibility for gas diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the size of carbon-based electrodes is increased to achieve larger surface area, then the electrode becomes more brittle and mechanically weaker
Solution Approach 1:
The electrode is divided into multiple sub-electrodes (first, second, third, fourth sub-electrodes) arranged in a modular configuration. Each sub-electrode maintains optimal mechanical properties while the collective assembly achieves the required large surface area. The sub-electrodes are connected through conductive adhesive to a current collector, creating a segmented structure that resolves the contradiction between size and strength.
2Productivity
If the electrode dimensions are increased to process larger volumes, then manufacturing becomes more difficult and energy-intensive
Solution Approach 1:
The electrode system uses multiple smaller sub-electrodes instead of one large electrode, enabling standard manufacturing processes to be used for each sub-electrode while achieving large total processing capacity. This modular approach avoids the need for energy-intensive casting or calendering of large single-piece electrodes.
Solution Approach 2:
The sub-electrodes are arranged and connected in a nested configuration on the current collector, with conductive adhesive bonding the sub-electrodes to the collector. This nested assembly approach allows efficient packaging and manufacturing of large-surface-area electrodes using conventional processes.
3Area of stationary object
If the electrode size is increased to reduce space requirements, then the electrode structure becomes more complex
Solution Approach 1:
The electrode is segmented into four sub-electrodes arranged in a systematic pattern on the current collector. This segmentation achieves large surface area while maintaining relatively simple structural organization through the use of conductive adhesive for connections, avoiding the need for complex assembly mechanisms.
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
This design enables the production of electrodes with significantly larger surface areas, improving mechanical stability and current distribution, reducing space and component requirements in electrochemical reactors, and enhancing the processing of large volumes of reactants.
Implementation Method 1
A carbon based electrode design featuring a conductive frame with cut-outs for sub-electrodes, ensuring mechanical robustness and uniform current distribution
Implementation Method 2
the porous gas diffusion electrode contained therein has been identified as a critical, but decisive component
Data Source
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AI summary
The present invention relates to a carbon based electrode with a large geometrical surface area comprising a frame of an electrically conductive material with several cut-outs with a surface area, which cut-outs are separated from each other by portions of the conductive material, wherein carbon based sub-electrodes dimensioned so as to a least cover the surface area of the cut-outs are positioned in the cut-outs and conductively connected to at least part of each of the portions of the conductive material adjacent to the carbon based sub-electrodes.