Electrochemical Cell Stack Layout Without Bipolar Plates
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Solution Overview
Problem
Existing electrochemical cell stacks using bipolar plates are costly and inefficient due to high material usage, contact resistances, and energy losses, with potential corrosion and complex designs.
Innovation Solution
An arrangement of electrochemical cells without bipolar plates, using electrically insulating separating elements and conductive connections between adjacent cells, allowing direct electrical contact through conductive connections that pass through the separating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bipolar plates are used to connect adjacent electrochemical cells, then electrical connection between cells is achieved, but material costs and device complexity increase significantly
Solution Approach 1:
The patent removes the bipolar plate component entirely from the electrochemical cell stack. Instead of using complex bipolar plates with integrated channels and connections, the invention extracts this function and replaces it with simple separating elements combined with separate electrically conductive connections, thereby reducing device complexity while maintaining electrical connection reliability
Solution Approach 2:
The patent segments the electrical connection function from the separating function. Rather than using a single integrated bipolar plate that performs both separation and electrical connection, the invention uses separate components: electrically insulating separating elements for isolation and separate electrically conductive connections for current flow, simplifying the overall structure
2Reliability
If bipolar plates with protective metal layers are used, then corrosion resistance is improved, but manufacturing costs and material usage increase
Solution Approach 1:
The patent replaces expensive bipolar plates requiring thick protective metal layers (nickel, platinum, gold) with inexpensive separating elements made from materials like plastic or ceramic that do not require costly protective coatings, significantly reducing material costs while maintaining adequate corrosion resistance for the application
Solution Approach 2:
The patent uses simple separating elements that copy the essential function of bipolar plates (separation and isolation) without replicating their complex structure and expensive material composition, achieving the same functional outcome with much simpler and cheaper components
3Reliability
If bipolar plates are used for cell connection, then electrical conductivity is achieved, but transition resistances cause energy losses
Solution Approach 1:
The patent introduces separate electrically conductive connections as intermediary elements that provide dedicated low-resistance pathways for current flow between cells. These specialized conductive connectors minimize transition resistance at the connection points, reducing energy losses while maintaining electrical conductivity
4Reliability
If thick metal layers are applied to bipolar plates for protection, then corrosion resistance improves, but material costs and production expenses increase
Solution Approach 1:
The patent replaces expensive bipolar plates requiring thick protective metal layers (nickel, platinum, gold) with inexpensive separating elements made from materials like plastic or ceramic that do not require costly protective coatings, significantly reducing material costs while maintaining adequate corrosion resistance for the application
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
Reduces material costs and energy losses, enhances efficiency by eliminating transition resistances, and allows for the use of lower-cost materials without compromising performance.
Implementation Method 1
a membrane arranged between the anode chamber and the cathode chamber
Implementation Method 2
the anodes being connected to the cathode of the electrochemical cell following in the stacking direction via at least one electrically conductive connection
Implementation Method 3
adjacent ones of the electrochemical cells being separated from one another by a respective electrically insulating separating element
Implementation Method 4
electrolysis of water
Data Source
AI summary
An arrangement comprising electrochemical cells arranged adjoining one another in a stacking direction (x), wherein adjacent ones of the electrochemical cells are separated from one another by a respective electrically insulating separating element, wherein the electrochemical cells each have an anode chamber comprising an anode, a cathode chamber comprising a cathode, and a membrane arranged between the anode and the cathode chambers, wherein the anodes are each connected to the cathode of the electrochemical cell following in the stacking direction (x) via an electrically conductive connection, and wherein the electrically conductive connections pass through the separating element arranged between the respective anode and the respective cathode, and/or a boundary of the electrochemical cells. The electrically conductive connection between the anodes and the cathodes makes it possible to dispense with bipolar plates in the described arrangement. The arrangement is more cost-effective to produce and more efficient in operation than known arrangements.