Integrated Current Carrier Frame for High-Pressure Unipolar Electrolysers
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Solution Overview
Problem
Unipolar electrochemical cells face challenges such as high resistance losses, complex assembly, limited ability to operate at elevated pressures, and restricted expansion of electroactive structures due to the use of elastomer-like materials and additional spacer gaskets, which hinder their scalability and efficiency in large-scale hydrogen production.
Innovation Solution
A combined current carrier, circulation chamber, and rigid support frame (CCF) is introduced, which is integrally formed and electrically conductive, supporting opposed electroactive structures with reduced parts and gaskets, allowing for increased conductivity and expandability, and facilitating high current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional unipolar cell design with elastomer materials and spacer gaskets is used, then assembly flexibility is improved, but device complexity and resistance losses increase
Solution Approach 1:
The patent combines the current carrier, circulation chamber, and frame into a single integrated CCF component. This merging eliminates the need for separate elastomer materials and spacer gaskets, reducing parts complexity while maintaining assembly flexibility through the unified design.
Solution Approach 2:
The CCF component performs multiple functions simultaneously: it serves as the current carrier for electrical conduction, the circulation chamber for fluid flow, and the frame for structural support. This multi-functionality eliminates the need for multiple separate components, reducing overall device complexity.
2Strength
If traditional unipolar cell design with additional spacer gaskets is used, then structural support is improved, but ability to operate at elevated pressures is limited
Solution Approach 1:
By integrating the frame structure directly into the CCF component, the design eliminates reliance on separate spacer gaskets for structural support. The unified CCF structure provides inherent strength to withstand elevated pressures while maintaining structural integrity.
3Ease of operation
If traditional unipolar cell design with elastomer-like materials is used, then ease of assembly is improved, but conductivity and expandability are restricted
Solution Approach 1:
The integration of the current carrier function directly into the CCF component ensures continuous, reliable electrical conduction pathways. The unified structure eliminates potential contact resistance issues that would arise from assembling multiple separate conductive components, thereby improving conductivity reliability.
Solution Approach 2:
The CCF's multi-functional design allows it to serve as both the structural frame and the electrical current carrier. This eliminates the need for separate elastomer materials that would compromise electrical conductivity, while the modular CCF design maintains ease of assembly.
4Ease of manufacture
If traditional unipolar cell design with multiple components is used, then manufacturing flexibility is improved, but manufacturing precision and part count increase
Solution Approach 1:
By consolidating the current carrier, circulation chamber, and frame into a single CCF component, the patent reduces the number of parts that require precise alignment during assembly. This integration maintains manufacturing flexibility through standardized CCF production while significantly improving assembly precision by eliminating multiple interfaces.
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 CCF design enhances conductivity, reduces part count, and enables operation under elevated pressures, enabling large-scale unipolar electrolysers with maximized surface areas and currents, suitable for renewable hydrogen production.
Implementation Method 1
The rigid support frame is electrically conductive and capable of carrying a current to the pair of electroactive structures
Implementation Method 2
a circulation chamber that extends across a first and second opposed face of the rigid support frame... for the circulation of electrolyte, products, and reactants
Implementation Method 3
suitable for use in the electrolysis of an alkali aqueous solution of water and an alkali metal chloride
Data Source
AI summary
Disclosed is a combined electrical current carrier, circulation chamber and frame (CCF) formed as a single or double part (CCF) for use in unipolar electrochemical devices, such as a filter press electrolyser apparatus. The CCF is structured to define an internal circulation chamber for circulation of electrolyte, products, and reactants as well as apertures which form flow passageways when the filter press device is assembled. Affixed on opposed surfaces of the CCFs are electrically conductive planar electroactive structures which are in electrical contact with the CCF. The circulation chamber is formed by the depth of the CCF itself between opposing electroactive structures. Multiple CCFs are assembled and compressed together to form the filter press electrolyser apparatus. The flow passageway apertures within the assembled filter press electrolyser are aligned to form flow pathways, located above and below the circulation chambers. Reactants and electrolyte are input along the bottom flow pathways. When power is applied to the CCFs and electroactive structures, the reactants, once they flow into the circulation chamber with the electrolyte, undergo redox reactions to produce the products which are then collected and exit the electrolyser in the upper flow pathways.