Electrolyser Frame with Integrated Sealing and Insulation
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Solution Overview
Problem
Existing electrolyser modules of filterpress type face challenges such as laborious assembly, gas leakages due to manual stacking and bolted connections, non-uniform current distribution, and secondary electrolysis, which reduce efficiency and gas quality.
Innovation Solution
A modular design featuring a closed frame with integrated sealing and electric insulating material, allowing for horizontal or vertical assembly, smaller bipolar plate diameters, and a one-step manufacturing process that eliminates bolting, enhancing sealing and insulation, enabling zero-gap design for improved current distribution and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking and bolting connections are used in existing electrolyser modules, then assembly is straightforward with traditional methods, but gas leakages occur and assembly becomes laborious and time-consuming
Solution Approach 1:
The patent merges the frame, sealing elements, and insulating material into a single integrated module. The frame is covered with sealing and insulating material that forms integral seals between modules, eliminating the need for separate gaskets and bolting connections. This integration resolves the contradiction by enabling both efficient assembly (through simple module stacking) and reliable sealing (through integrated seals that prevent gas leakages).
Solution Approach 2:
The patent segments the electrolyser into discrete, self-contained modules that can be stacked independently. Each module includes a frame covered with sealing and insulating material, creating modular units that assemble through simple stacking without requiring manual bolting or alignment of separate sealing components. This segmentation improves productivity while maintaining sealing reliability through the integrated design of each module.
2Strength
If steel frames with separate gaskets are used, then structural strength is provided, but secondary electrolysis occurs in gas channels and assembly becomes complex
Solution Approach 1:
The patent uses composite material construction where the frame is covered with sealing and insulating material, creating a composite structure that combines the mechanical strength of the frame with the electrical insulation and sealing properties of the covering material. This composite design provides structural strength while preventing secondary electrolysis by electrically isolating the gas channels from the conductive frame material.
3Reliability
If bipolar plates have outer diameter equal to diaphragm frame, then full frame coverage is achieved, but module diameter increases and stacking becomes more difficult
Solution Approach 1:
The patent enables flexible module design where the bipolar plate diameter can be smaller than the frame diameter, allowing adaptive configuration. The integrated sealing and insulating material coverage ensures reliable sealing regardless of the bipolar plate size relative to the frame, enabling both full frame coverage and simplified stacking with smaller, more manageable module dimensions.
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 modular design facilitates efficient stacking, reduces ohmic resistance, enhances gas transport, and increases production capacity while ensuring higher safety and uniform current distribution, minimizing leakages and secondary electrolysis.
Implementation Method 1
said material provides sealing against a possible adjacent module or an end section of said electrolyser
Implementation Method 2
said material at least partly covers the surface of the frame... provides sealing and electric insulating material
Implementation Method 3
enabling zero-gap when stacked in an electrolysis cell leading to lower ohmic resistance and thus higher energy efficiency
Implementation Method 4
enhances gas transport when used in an electrolysis cell and thereby higher efficiency for the production of preferred gases
Implementation Method 5
Electrolysers of filter press type are commonly used for the production of hydrogen and oxygen from brines and lyes
Data Source
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Figure 3
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AI summary
The present invention comprises a module for an electrolyser of filterpress type comprising at least one closed frame defining at least one first opening, wherein said module comprises a sealing and electric insulating material, wherein said material at least partly covers the surface of the frame. In addition the present invention comprises a method for producing a module for an electrolyser of filterpress type and use thereof. Further the present invention comprises use of a pressure element.