Composite Cell Plate for Electrochemical Cells
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Solution Overview
Problem
Electrolyser cell hardware made from polymer materials faces challenges in pressure retention, dimensional stability, and resistance to hoop stress, especially at high pressures, leading to costly and impractical solutions such as full steel construction or external pressure jackets, which are not cost-effective for large-scale production.
Innovation Solution
A composite cell plate design featuring a resilient metal element laterally interlocked with a polymer element, using engineering polymers like polyphenylene sulphide or polyether ether ketone, with spigots and apertures for engagement, minimizes hoop stress and strain, allowing for high-pressure operation while maintaining cost-effectiveness and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer material is used for cell hardware, then cost-effectiveness and manufacturability are improved, but pressure retention and resistance to hoop stress deteriorate
Solution Approach 1:
The patent applies composite materials by combining polymer elements with metal reinforcement elements (such as steel or stainless steel rings) to create a hybrid structure. The polymer provides cost-effectiveness and ease of manufacture, while the metal reinforcement provides the necessary strength to resist hoop stress at high pressures. This composite approach allows the cell hardware to meet both manufacturing and performance requirements.
2Strength
If full steel construction is used, then resistance to hoop stress is improved, but cost and weight increase
Solution Approach 1:
The patent applies local quality by placing metal reinforcement elements only in specific locations where hoop stress is highest, rather than using full steel construction. The metal rings or reinforcement elements are positioned circumferentially within the polymer cell plate to provide localized strength enhancement. This allows the structure to resist hoop stress effectively while minimizing the amount of heavy metal material used, thereby reducing overall weight compared to full steel construction.
3Strength
If full steel construction is used, then resistance to hoop stress is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses composite materials combining polymer and metal components to achieve the necessary strength at lower cost. The polymer elements can be manufactured using cost-effective processes such as injection molding, while the metal reinforcement elements are added only where needed. This hybrid approach significantly reduces material costs compared to full steel construction while still providing adequate resistance to hoop stress for high-pressure operation.
4Stress or pressure
If external pressure jacket is used, then pressure retention is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the structural functions by integrating the reinforcement elements directly within the cell plate structure itself, rather than using a separate external pressure jacket. The metal rings are embedded within or attached to the polymer cell plate, combining the load-bearing function with the cell structure. This integration reduces device complexity by eliminating separate containment components while maintaining effective pressure retention through the reinforced cell plate design.
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 composite cell plate design effectively reduces hoop stress, enhances long-term strain resistance, and enables safe operation at high pressures, demonstrated by finite element analysis and cyclic testing, with a significant reduction in component count and assembly complexity, resulting in a durable and cost-effective solution for electrochemical cells.
Implementation Method 1
a resilient metal element laterally interlocked, at a plurality of engagement points, with a polymer element
Implementation Method 2
laterally interlocked, at a plurality of engagement points, with a polymer element
Data Source
Figure 1
AI summary
A composite cell plate comprises a polymer element laterally mated and interlocked, at a plurality of engagement points, with a resilient metal element. The cell plate can be used in an electrochemical cell.