Electrochemical Cell Gas Diffusion Layer for Hole-Edge Integrity

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Solution Overview

Problem

The gas diffusion layer in existing electrochemical cells is prone to damage, such as cracking or peeling, due to distortion at the connecting holes of the metal support.

Innovation Solution

The gas diffusion layer is designed with a protruding portion that covers a portion of the inner circumferential surface of the connecting holes, tapering away from the body portion in both thickness and surface directions, and has a higher covering width and pore diameter ratio compared to the first electrode layer, with an oxide film thickness variation at the metal support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If through holes are formed in the gas diffusion layer to enable gas supply and discharge, then gas diffusion performance is improved, but the gas diffusion layer becomes vulnerable to damage from connecting hole distortion

Engineering Contradiction:

Improvegas diffusion performanceVSAvoidgas diffusion layer integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The protruding portion is formed in advance within the connecting hole before the gas diffusion layer is fully assembled. This preliminary structure provides pre-positioned support that prevents distortion from occurring during operation, thereby protecting the gas diffusion layer while maintaining through-hole functionality for gas supply and discharge

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protruding portion acts as an intermediary element between the connecting hole structure and the gas diffusion layer. It mediates the mechanical stress and distortion forces, preventing them from directly affecting the gas diffusion layer while still allowing gas to pass through the through holes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the gas diffusion layer is made thicker to prevent damage, then structural strength is improved, but gas diffusion efficiency decreases

Engineering Contradiction:

Improvegas diffusion layer strengthVSAvoidgas diffusion efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Instead of uniformly thickening the entire gas diffusion layer, the protruding portion provides localized reinforcement only at the critical connecting hole regions. This maintains thin overall thickness for efficient gas diffusion while adding strength precisely where distortion forces are applied

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The gas diffusion layer is functionally segmented into different thickness zones: the main body remains thin for optimal gas diffusion, while the protruding portion at the connecting holes provides localized thickening for mechanical strength and distortion resistance

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250297383A1Electrochemical cell

Publication Date: 2025.09.25 NGK INSULATORS LTD

AI summary

An electrochemical cell includes a metal support having a plurality of connecting holes formed in a principal surface and a cell body disposed on the principal surface. The cell body has a gas diffusion layer disposed on the principal surface, a first electrode layer disposed on the gas diffusion layer, a second electrode layer and an electrolyte layer disposed between the first electrode layer and the second electrode layer. The gas diffusion layer has a body portion located in a gap between the metal support and the first electrode layer and a protruding portion protruding from the body portion to the connecting holes. The protruding portion covers a portion of an inner circumferential surface of the connecting hole.