Composite Separator Plate Structure for Sealing and Media Guidance

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Solution Overview

Problem

Conventional electrolysers face challenges in optimizing separator plates for both media guidance and sealing due to conflicting requirements of formability, corrosion resistance, mechanical stability, and leaktightness, often resulting in suboptimal designs and complex sealing arrangements.

Innovation Solution

A separator plate comprising two distinct metal plates connected in a materially bonded manner, where one plate is optimized for media guidance and the other for sealing, differing in material properties and thicknesses, such as titanium for formability and stainless steel for strength, with integrated sealing elements and potential pressure-equalizing openings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the separator plate uses a single material optimized for corrosion resistance, then corrosion resistance is improved, but formability and mechanical stability deteriorate

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidformability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The separator plate is constructed as a composite structure with a first plate (titanium or titanium alloy) providing corrosion resistance and formability for the flow field, and a second plate (stainless steel or stainless steel alloy) providing mechanical strength and sealing stability. This composite material approach allows each layer to be optimized for its specific function, resolving the contradiction between corrosion resistance and formability.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If the separator plate uses a single material optimized for formability, then ease of manufacture is improved, but mechanical stability and sealing performance deteriorate

Engineering Contradiction:

ImproveformabilityVSAvoidmechanical stability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The first plate is made of titanium or titanium alloy which offers excellent formability for creating complex flow field channel structures, while the second plate is made of stainless steel or stainless steel alloy which provides superior mechanical strength and sealing stability. This division allows the flow field to be easily formed while the sealing region maintains high mechanical stability.

Inventive Principle:

Principle #40Composite materials

3Strength

If the separator plate uses a single material optimized for mechanical stability, then strength is improved, but corrosion resistance and formability deteriorate

Engineering Contradiction:

Improvemechanical stabilityVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The first plate (titanium or titanium alloy) provides excellent corrosion resistance for the flow field region where it contacts process media, while the second plate (stainless steel or stainless steel alloy) provides high mechanical strength for the sealing region. This composite structure ensures both corrosion resistance and mechanical stability are optimized in their respective regions.

Inventive Principle:

Principle #40Composite materials

4Device complexity

If the separator plate integrates both media guidance and sealing functions in a single plate, then device complexity is reduced, but performance optimization deteriorates

Engineering Contradiction:

Improvestructure simplicityVSAvoidperformance optimization

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The separator plate is segmented into two distinct plates: a first plate dedicated to media guidance with flow field channel structures, and a second plate dedicated to sealing with sealing elements in the sealing region. This segmentation allows each plate to be independently optimized for its specific function while still forming an integrated separator plate assembly.

Inventive Principle:

Principle #1Segmentation

5Reliability

If additional sealing elements and cell frames are added to improve sealing, then leaktightness is improved, but device complexity increases

Engineering Contradiction:

ImproveleaktightnessVSAvoidsealing arrangement complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sealing function is merged directly into the separator plate structure itself through the second plate made of stainless steel or stainless steel alloy, which provides inherent sealing stability and leaktightness. This eliminates or reduces the need for separate sealing elements and simplifies the overall sealing arrangement while maintaining high reliability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240175152A1Separator plate for an electrochemical system, comprising two different individual plates

Publication Date: 2024.05.30 REINZ DICHTUNGS G M B H

AI summary

A separator plate, an assembly for an electrochemical system, and an electrochemical system, the separator plate comprising a first metal plate, the first plate having a flow field with channel structures integrally formed in the first plate for guiding a reaction medium or product medium along the first plate. A second metal plate having at least one sealing element for sealing off at least one region of the separator plate. The first plate and the second plate differ from each other in at least one material property and/or in their material thicknesses and the first plate and the second plate are connected to each other in a materially bonded manner.