Electrolysis Cell Surface Contacts for Weld-Free High-Current Operation
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Solution Overview
Problem
Existing electrolysis cell designs face inefficiencies at high current densities due to uneven current distribution and require labor-intensive welded connections, leading to high manufacturing costs and difficult refurbishment processes.
Innovation Solution
An electrolysis cell design with surface contact connections between cell components, eliminating the need for welding, allowing for easy assembly and refurbishment, and using contact improving coatings to enhance electrical conductivity in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded connections are used to fix electrodes to support units and back walls, then electrical connection reliability and durability are improved, but manufacturing complexity and cost increase, and refurbishment difficulty increases
Solution Approach 1:
The electrode assembly is segmented into separable components: the electrode, electrode support unit, and back wall connection elements. This allows the electrode to be independently removed and replaced without affecting the structural integrity of the back wall or requiring destruction of welded joints, thus enabling easy refurbishment while maintaining reliable electrical connection during operation.
Solution Approach 2:
An intermediate connection element (such as a clamp, holder, or connector) is introduced between the electrode support unit and the back wall. This intermediary component provides a reliable electrical connection during operation but can be easily detached when refurbishment is needed, thus resolving the contradiction between connection reliability and ease of refurbishment.
2Reliability
If welded connections are used to ensure leak-tightness, then connection reliability is improved, but minimum sheet thickness requirements and manufacturing cost increase
Solution Approach 1:
A separate sealing element or gasket is introduced as an intermediary component between the back wall and the electrode support unit assembly. This sealing element provides reliable leak-tightness without requiring thick metal sheets or complex welded joints, thereby reducing manufacturing cost while maintaining connection reliability.
Solution Approach 2:
A flexible sealing film or gasket is used to provide leak-tight connection between components. This thin-film sealing solution eliminates the need for thick metal sheets required for welded connections, reducing material cost and manufacturing complexity while ensuring reliable sealing.
3Duration of action of stationary object
If electrodes are connected to back walls via welded support units, then electrical connection stability is improved, but refurbishment difficulty and risk of damage increase
Solution Approach 1:
The electrical connection path is segmented into separable stages: back wall to support unit, and support unit to electrode. The electrode and support unit can be detached as a module for refurbishment, while the back wall connection remains intact. This segmentation maintains stable electrical connection during operation but enables easy refurbishment by simply replacing the electrode or support unit without damaging the back wall.
4Ease of manufacture
If surface contact connections are used instead of welding, then ease of manufacture and refurbishment are improved, but electrical connection reliability may deteriorate
Solution Approach 1:
The surface contact connection parameters are optimized by increasing contact pressure, enlarging contact surface area, and using high-conductivity contact materials. These parameter changes ensure that the non-welded surface contact connection achieves electrical conductivity and reliability comparable to welded joints, while maintaining ease of manufacture and refurbishment.
Solution Approach 2:
Composite contact elements are used that combine highly conductive materials with high mechanical strength and high contact pressure capability. This composite material approach ensures reliable electrical connection through surface contact while maintaining manufacturing simplicity and ease of assembly/disassembly.
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
Facilitates efficient operation at high current densities with reduced manufacturing costs and simplified refurbishment, while maintaining electrical integrity and preventing corrosion.
Implementation Method 1
the electrical connection between the back wall and the electrode support unit and/or between the electrode support unit and the electrode is provided by means of a surface contact connection. The surface contact connection according to the invention establishes the electrical connection by a surface contact pressure between the connected cell components
Implementation Method 2
the electrode support units provide an electrical connection between the back wall and the electrode in each of the electrode chambers
Implementation Method 3
contact improving coatings to enhance electrical conductivity in harsh environments
Implementation Method 4
a sheet-like separator that is interposed in a joint between the two cell elements and provides a separating wall between the electrode chambers
Data Source
AI summary
An electrolysis cell for chlor-alkali or alkaline water electrolysis comprises two cell elements each defining an electrode chamber by providing a back wall and sidewalls of the electrode chambers, and a sheet-like separator being interposed in a joint between the two cell elements and providing a separating wall between the electrode chambers, wherein an electrode and an electrode support unit is accommodated in each of the electrode chambers, wherein the electrode support units provide an electrical connection between the back wall and the electrode in each of the electrode chambers, wherein the electrodes are in direct contact with the sheet-like separator, and wherein at least in one of the electrode chambers the electrical connection between the back wall and the electrode support unit and/or between the electrode support unit and the electrode is provided by means of a surface contact connection.