Electrode System Internal Busbar Connections
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Solution Overview
Problem
Existing electrode stack systems for electrolysis have bulky mechanical connections between power sources and electrodes, making installation laborious and inefficient.
Innovation Solution
An electrode system with internal busbar connections through the electrode stack, featuring alternating first and second electrode plates with specific busbar openings and dimensions, allowing for reduced external footprint and enhanced current transfer via threaded and locking mechanisms, and the use of conductive spacers for increased contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external busbar connections are used for electrode stacks, then mechanical connection between power source and electrodes is achieved, but the external footprint becomes bulky and installation becomes laborious
Solution Approach 1:
The busbars are nested within the electrode stack structure itself, with openings provided directly in the electrode plates for busbar passage. This integration eliminates external connection components and reduces the overall external footprint while maintaining electrical connectivity.
Solution Approach 2:
The busbar connection function is merged with the electrode plate structure by providing openings directly in the plates. The electrode plates serve dual purposes: as electroactive components and as structural elements that facilitate internal busbar routing, eliminating separate connection hardware.
2Reliability
If busbars extend through electrode plates, then electrical connection is achieved, but mechanical contact area and connection stability are insufficient
Solution Approach 1:
The connection interface transitions from a simple linear passage to a multi-dimensional engagement system. Busbars feature protrusions that engage with corresponding recesses in the electrode plates, creating point contacts that distribute mechanical stress and enhance connection stability across multiple spatial dimensions.
Solution Approach 2:
Protrusions and recesses act as intermediary features between the busbar and electrode plate. These intermediate geometric features increase the effective contact area and provide mechanical interlocking, thereby enhancing connection reliability without requiring complex fastening mechanisms.
3Ease of manufacture
If uniform busbar openings are provided in all electrode plates, then manufacturing is simplified, but electrical isolation between alternating electrodes cannot be ensured
Solution Approach 1:
Different electrode plates are provided with different opening configurations tailored to their specific electrical requirements. First electrode plates have first-type openings for one polarity, while second electrode plates have second-type openings for the opposite polarity, ensuring proper electrical isolation and connectivity throughout the stack.
Solution Approach 2:
The electrode stack employs asymmetric opening patterns where alternating plates have differently dimensioned and positioned busbar openings. This asymmetry ensures that busbars connect to electrodes of the correct polarity while maintaining electrical isolation between adjacent electrodes of opposite polarity.
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
This design minimizes external bulk, facilitates easier installation, and improves current transfer efficiency by ensuring mechanical and electrical contact within the electrode stack, optimizing power delivery to the electrodes.
Implementation Method 1
a first busbar extending through the first electrode plate first busbar openings and the second electrode plate first busbar openings, the first busbar being configured to be in mechanical contact with an inner first busbar surface of the first electrode plate first busbar openings only
Data Source
AI summary
An electrode system comprising: a plurality of first electrode plates (3) and a plurality of second electrode plates (5′) arranged alternatingly to form an electrode stack, each first electrode plate having a first electrode plate first busbar opening and a first electrode plate second busbar opening extending through the first electrode plate, the first electrode plate second busbar opening being larger than the first electrode plate first busbar opening, each second electrode plate (5′) having a second electrode plate first busbar opening (27a′) extending through the second electrode plate (5′), the second electrode plate first busbar opening (27a′) being dimensioned larger than each of the first electrode plate first busbar openings and aligned with the first electrode plate first busbar openings, and a second electrode plate second busbar opening (27b′) extending through the second electrode plate (5′), the second electrode plate second busbar opening (27b′) being dimensioned smaller than each of the first electrode plate second busbar openings and aligned with the first electrode plate second busbar openings, a first busbar extending through the first electrode plate first busbar openings and the second electrode plate first busbar openings (27b′), the first busbar being configured to be in mechanical contact with an inner first busbar surface of the first electrode plate first busbar openings only, and a second busbar extending through the first electrode plate second busbar openings and the second electrode plate second busbar openings (27b′), the second busbar being configured to be in mechanical contact with an inner second busbar surface of the second electrode plate second busbar openings (27b′) only.