Offset Corrugated Fuel Electrode for Electrolyte Flow and Rigidity
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Solution Overview
Problem
Existing fuel electrodes for electrochemical power systems face challenges such as high cost, irregular pore structures leading to flow restrictions and reduced surface area over time, dendrite formation, and susceptibility to bowing, which can cause short circuits and reduce efficiency.
Innovation Solution
A corrugated fuel electrode design comprising multiple offset corrugated portions made of conductive material, with apertures and attachments to enhance surface area, structural rigidity, and electrolyte flow, minimizing dendrite formation and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If porous metal fuel electrodes are used to provide high surface area to volume ratio, then the surface area for fuel deposition is improved, but the cost becomes prohibitive and the irregular pore structure creates flow restrictions and reduces electrolyte exchange rates
Solution Approach 1:
The fuel electrode is divided into multiple corrugated portions with different orientations (first corrugated portion, second corrugated portion, third corrugated portion) that are attached together. This segmentation creates a high surface area structure without requiring expensive porous materials, as each corrugated portion contributes additional surface area while maintaining open, regular geometry for efficient electrolyte flow
Solution Approach 2:
The patent uses relatively inexpensive corrugated metal portions instead of expensive porous metals. The corrugated structure achieves high surface area through geometric configuration rather than material porosity, providing a cost-effective alternative that maintains structural integrity and electrochemical performance
2Area of moving object
If porous metal fuel electrodes are used to provide high surface area to volume ratio, then the surface area for fuel deposition is improved, but the tortuous pore path restricts electrolyte flow and reduces exchange and reaction rates
Solution Approach 1:
The electrode is segmented into multiple corrugated portions with different orientations attached together. This creates a three-dimensional structure with high surface area that maintains open pathways for electrolyte flow, avoiding the tortuous paths of porous materials while maximizing reactive surface area
Solution Approach 2:
The patent transitions from a flat two-dimensional electrode to a three-dimensional corrugated structure by adding depth through multiple offset corrugated portions. This dimensional change increases surface area while maintaining direct, unobstructed pathways for electrolyte access to all surfaces
3Ease of manufacture
If fuel electrode is made as a flat sheet to reduce cost, then the manufacturing cost is reduced, but the electrode becomes susceptible to bowing and flexing which can cause short circuits
Solution Approach 1:
The flat sheet is segmented into multiple corrugated portions that are attached together. This segmentation creates a rigid three-dimensional structure that resists bowing and flexing while maintaining cost-effectiveness, as the rigid geometry prevents deformation that could lead to short circuits
Solution Approach 2:
The patent introduces curvature through corrugations in multiple orientations. These curved, rigid geometric features provide structural stability and prevent the electrode from flexing or bowing, eliminating the short circuit risk associated with flat sheets while keeping manufacturing costs low
4Reliability
If spacers or separators are added to prevent fuel electrode bowing, then short circuit prevention is improved, but the surface area available for reaction is reduced and electrolyte flow is restricted
Solution Approach 1:
The patent merges the structural support function with the reactive surface function by making the corrugated portions themselves provide both rigidity and high surface area. This eliminates the need for separate spacers that would block reactive surfaces, as the corrugated structure inherently provides both mechanical stability and electrochemical activity
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 corrugated design provides a high surface area to volume ratio, reduces dendrite formation, and enhances structural stability, ensuring efficient fuel deposition and prolonged run time while maintaining electrolyte flow and preventing short circuits.
Implementation Method 1
A first corrugated portion (210) is formed of an electroconductive material. The first corrugated portion has a first corrugation axis
Implementation Method 2
formed of an electroconductive material
Implementation Method 3
comprises a plurality of apertures therethrough
Data Source
AI summary
A fuel electrode incorporates a first and second corrugated portion that are attached to each other at offset angles respect to their corrugation axis and therefore reinforce each other. A first corrugated portion may extend orthogonally with respect to a second corrugated portion. The first and second corrugated portions may be formed from metal wire and may therefore have a very high volumetric void fraction and a high surface area to volume ratio (sa/vol). In addition, the strands of the wire may be selected to enable high conductivity to the current collectors while maximizing the sa/vol. In addition, the shape of the corrugation, including the period distance, amplitude and geometry may be selected with respect to the stiffness requirements and electrochemical cell application factors. The first and second corrugated portions may be calendared or crushed to reduce thickness of the fuel electrode.