Electrochemical Cell Interconnecting Layers for Low-Impedance Conduction
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Solution Overview
Problem
Existing electrochemical cells face high electrical impedance and inefficient multi-phase junctions at the catalyst, proton exchange membrane, and gas diffusion layer interfaces, leading to energy loss and thermal management issues, particularly on the anode side, which are inadequate for future applications requiring higher efficiency and lower costs.
Innovation Solution
The implementation of a plurality of interconnecting layers between the electrode and membrane, comprising local and global interconnecting layers with hierarchical structures, optimized for vertical conduction and multi-phase junctions, using conductive materials like metals and polymers to enhance electrical conductivity and fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple electrochemical cells are connected in parallel within a single can, then the power output and capacity are improved, but the risk of internal short circuits and thermal runaway increases
Solution Approach 1:
An insulating layer is introduced as an intermediary between adjacent electrochemical cells to prevent direct contact and potential short circuits. The insulating layer acts as a mediator that maintains electrical isolation while allowing thermal and mechanical interaction, thereby enabling safe parallel connection of multiple cells within a single can.
Solution Approach 2:
The insulating function is extracted from the cell housing structure and implemented as a separate, dedicated insulating layer between cells. This separation of functions allows the cell housing to focus on structural support while the insulating layer specifically addresses electrical isolation, improving overall system reliability.
2Quantity of substance
If multiple electrochemical cells are connected in parallel within a single can, then the energy density is improved, but the thermal management difficulty increases
Solution Approach 1:
The insulating layer is designed to perform multiple functions simultaneously: electrical insulation, thermal management, and mechanical spacing. By integrating these functions into a single component, the patent achieves high energy density through compact cell arrangement while maintaining effective thermal control across multiple cells.
Solution Approach 2:
The insulating layer serves as a thermal intermediary between adjacent cells, facilitating controlled heat transfer while preventing thermal runaway propagation. This mediator approach enables efficient thermal management in high-density cell configurations by regulating heat flow paths between cells.
3Manufacturing precision
If a coating layer is applied to the outer surface of the current collector, then the manufacturing precision and cell performance are improved, but the manufacturing complexity increases
Solution Approach 1:
The coating layer application is integrated into the existing current collector manufacturing process, combining the coating function with the current collector production. This merging of processes achieves precise coating uniformity while avoiding the need for separate, complex coating equipment and procedures.
Solution Approach 2:
The coating layer is applied in advance during current collector manufacturing, before assembly into the electrochemical cell. This preliminary action ensures uniform coating distribution and eliminates the need for post-assembly coating operations, thereby reducing overall manufacturing complexity while maintaining high precision.
Data Source
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AI summary
The following disclosure relates to electrochemical or electrolysis cells and components thereof. In one example, the cell includes an electrode, a membrane, and a plurality of interconnecting layers positioned between the electrode and the membrane. The plurality of interconnecting layers includes a local interconnecting layer positioned adjacent to the membrane and a global interconnecting layer positioned adjacent to the electrode. Further, the plurality of interconnecting layers provides a vertical conduction in a direction extending along an axis running between the electrode and the membrane.