Electrolysis Anode With Porous Metal Substrate And Optimized Pore Geometry
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Solution Overview
Problem
Conventional anodes, such as DSA, experience high overvoltage initially during electrolysis, leading to increased power consumption, and existing designs fail to adequately reduce electrolysis voltage while maintaining practical strength.
Innovation Solution
The electrode for electrolysis is designed with a conductive substrate of porous metal and a catalyst layer, having a thickness between 0.5 mm and 1.2 mm, and a specific value obtained by dividing the sum of perimeters of openings by the opening ratio, within the range of 2 mm to 5 mm, along with controlled center-to-center distances of openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the thickness of anode is reduced to lower electrolysis voltage, then voltage and power consumption are reduced, but the strength and durability of the electrode deteriorate
Solution Approach 1:
The anode combines expanded metal base material (providing strength) with catalyst coating layer (providing electrochemical activity). This composite structure allows the electrode to maintain practical strength while achieving low electrolysis voltage through optimized catalyst distribution and pore structure.
Solution Approach 2:
The anode uses expanded metal with controlled pore size, distribution, and ratio. The porous structure reduces electrolysis voltage by improving electrolyte penetration and catalyst accessibility, while the expanded metal framework maintains mechanical strength despite reduced thickness.
2Use of energy by moving object
If the opening ratio of anode is increased to reduce electrolysis voltage, then voltage and power consumption are reduced, but the structural integrity and strength of the electrode deteriorate
Solution Approach 1:
The invention optimizes specific parameters including opening ratio (5-40%), pore size (0.1-2.0 mm), and their ratio (0.05-0.5 mm²). By controlling these parameters within specific ranges, the anode achieves low electrolysis voltage while maintaining sufficient strength for practical application.
3Object-generated harmful factors
If conventional DSA anode is used, then chlorine generation capability is achieved, but high initial overvoltage occurs leading to increased power consumption
Solution Approach 1:
The anode applies catalyst coating selectively on the expanded metal surface with controlled coverage and distribution. This local quality optimization ensures efficient chlorine generation at active sites while minimizing overall overvoltage and power consumption compared to conventional DSA.
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 effectively reduces voltage and power consumption during electrolysis while maintaining practical strength, making it suitable for sodium chloride electrolysis by ion exchange membrane process.
Implementation Method 1
Sodium chloride electrolysis by ion exchange membrane process is a method for electrically decomposing (electrolyzing) brine by use of an electrode for electrolysis to produce caustic soda, chlorine and hydrogen
Implementation Method 2
at least one catalyst layer formed on a surface of the conductive substrate
Data Source
Figure 1(a)~3
Figure 4(A)~4(C)
Figure 5~6
AI summary
An electrode for electrolysis including a conductive substrate formed of a porous metal plate, and at least one catalyst layer formed on a surface of the conductive substrate, wherein the electrode for electrolysis has a thickness of more than 0.5 mm and 1.2 mm or less; and value C, which is obtained by dividing sum B of perimeters of openings of the electrode for electrolysis by opening ratio A of the electrode for electrolysis, is more than 2 and 5 or less.