Electrochemical Cell Interconnecting Layers for Low-Impedance Interfaces
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Solution Overview
Problem
Existing electrochemical cells face high electrical impedance and inefficient multi-phase junctions at the interface of catalyst, water, electrical conductor, proton transport, and bubble formation/gas transport, leading to energy loss and thermal management issues, particularly on the anode side, which are inadequate for future applications like hydrogen production for fertilizer manufacturing or steel production.
Innovation Solution
The implementation of a plurality of interconnecting layers, including local, mid-level, and global layers, positioned between the electrode and membrane, with specific conductive materials and patterns to enhance vertical conduction and maximize multi-phase interfaces, optimizing electrical and proton transport while allowing fluid flow and gas egress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional random coating of catalyst and PEM material onto PEM layer and GDL is used, then the interface structure is simple to manufacture, but electrical impedance is too high and energy loss exceeds 50%
Solution Approach 1:
The interface is segmented into distinct functional layers: a PEM layer, a GDL layer, and an interconnecting layer with vertical conductors. This segmentation allows each layer to be optimized for its specific function while reducing overall energy loss through improved electrical conductivity pathways.
Solution Approach 2:
An interconnecting layer is introduced as an intermediary between the PEM and GDL layers. This intermediate layer contains vertical conductors that mediate electrical transport between the two layers, significantly reducing contact resistance and energy loss at the interface.
2Reliability
If titanium is used for anode GDL to withstand oxidizing acidic environment, then corrosion resistance is improved, but electrical conductivity deteriorates and cost increases due to platinum coating
Solution Approach 1:
The interconnecting layer with vertical conductors acts as an intermediary that provides low-resistance electrical pathways without requiring the entire GDL structure to be highly conductive. This allows the use of corrosion-resistant but less conductive materials like titanium in the GDL while maintaining overall electrical performance.
Solution Approach 2:
Electrical conductivity is localized to specific vertical conductors within the interconnecting layer rather than requiring uniform conductivity throughout the entire GDL. This allows different regions to have different properties: corrosion-resistant titanium in the GDL and highly conductive materials in the vertical conductors.
3Adaptability or versatility
If multiple interfaces are required for catalyst, water, electrical conductor, proton transport, and bubble formation, then functional completeness is improved, but impedance losses increase and thermal management becomes difficult
Solution Approach 1:
The interface design incorporates vertical conductors that extend in the third dimension (perpendicular to the membrane plane), creating three-dimensional multi-phase junctions. This dimensional transition allows multiple functions (catalyst support, electrical conduction, proton transport, gas evolution) to be integrated in a compact vertical architecture, reducing the number of separate two-dimensional interfaces and minimizing total impedance losses.
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 configuration reduces impedance losses to less than 5 ohms, enabling operation at high current densities with reduced resistive loss, improving efficiency and reducing costs by enhancing electrical conductivity and maintaining fluid flow and bubble/gas removal.
Implementation Method 1
the plurality of interconnecting layers provides a vertical conduction in a direction extending along an axis running between the electrode and the membrane
Implementation Method 2
at the interface, protons and gas are needed to be removed
Data Source
AI summary
The following disclosure relates to electrochemical or electrolysis cells and components thereof. In one example, the cell includes an electrode, a membrane, and a plurality of interconnecting layers positioned between the electrode and the membrane. The plurality of interconnecting layers includes a local interconnecting layer positioned adjacent to the membrane and a global inter- connecting layer positioned adjacent to the electrode. Further, the plurality of interconnecting layers provides a vertical conduction in a direction extending along an axis running between the electrode and the membrane.