Electrochemical Separator Segmentation for Large Reaction Area

The reaction layer is divided into multiple small-sized reaction layers (first reaction layer, second reaction layer, etc.) arranged in an array. Each reaction layer maintains its structural integrity independently while collectively providing a large reaction region. The separator includes multiple reaction regions (first reaction region, second reaction region, etc.) that correspond to and support these segmented reaction layers, allowing the system to achieve both large total reaction area and individual layer strength.

Instead of manufacturing one large reaction layer that would require a huge apparatus and suffer from thickness deviations, the invention segments the reaction region into multiple smaller reaction layers. Each small reaction layer can be manufactured with consistent thickness using standard apparatus, and when arranged in an array, they collectively provide the desired large reaction area with uniform thickness control throughout.

The invention divides the large reaction region into multiple small reaction layers that can be manufactured using standard-sized apparatus. Each reaction layer is produced independently in a compact manufacturing process, then assembled into an array configuration. This segmentation approach eliminates the need for a huge manufacturing apparatus while achieving the desired large total reaction area through the collective arrangement of multiple small units.

Instead of increasing power by adding more stacks in series (increasing voltage), the invention enlarges the reaction area within each cell by arranging multiple small reaction layers in an array on a single separator. This two-dimensional expansion of the reaction region allows each cell to generate more current at the same voltage, thereby increasing power output without requiring additional stacks. The separator is designed with multiple reaction regions that accommodate this array configuration.