Electrolysis Electrode with Detachable Nickel Sintered Compact
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Solution Overview
Problem
Existing electrolysis systems face challenges with cathode degradation due to reverse current flow, particularly in larger electrolyzers, where the reverse current absorption performance is insufficient, leading to high material costs and complex maintenance procedures.
Innovation Solution
An electrode for electrolysis featuring a conductive substrate with a reverse current absorption body formed from a sintered compact containing nickel, which is directly coupled to the substrate or coated with wire gauze, eliminating the need for a substrate and enhancing reverse current absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reverse current absorption layer is formed by deposition technique onto a substrate, then cathode degradation is suppressed, but the substrate shape is large and complex making formation difficult and maintenance complicated
Solution Approach 1:
The patent applies porous sintered metal material as the reverse current absorption body, which provides high surface area for reverse current absorption while maintaining a simple compact form. The porous structure enables effective reverse current consumption without requiring complex substrate shapes or deposition techniques, thus resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent employs a replaceable reverse current absorption body made of inexpensive sintered metal material that can be easily detached and replaced when consumed. This approach eliminates the need for complex substrate structures and deposition processes, making both manufacturing and maintenance simple while effectively suppressing cathode degradation.
2Reliability
If a reverse current absorption layer is formed by deposition technique onto a substrate, then cathode degradation is suppressed, but maintenance costs increase due to complex procedures
Solution Approach 1:
The patent segments the reverse current absorption function from the substrate structure by using a separate, detachable reverse current absorption body. This allows the absorption body to be independently replaced when consumed, eliminating complex maintenance procedures associated with substrate-integrated layers and reducing maintenance costs while maintaining cathode protection.
Solution Approach 2:
The patent employs a replaceable reverse current absorption body made of inexpensive sintered metal material that can be easily detached and replaced when consumed. This approach eliminates the need for complex substrate structures and deposition processes, making both manufacturing and maintenance simple while effectively suppressing cathode degradation.
3Productivity
If the electrolyzer size increases with more electrolytic cells, then production capacity increases, but reverse current size increases proportionally to the square of the number of cells
Solution Approach 1:
The patent employs porous sintered metal material with high surface area and high discharge capacity, enabling the reverse current absorption body to effectively consume large reverse currents generated in large-scale electrolyzers with multiple cells, thus protecting the cathode while maintaining high production capacity.
4Quantity of substance
If Ruthenium is used as cathode catalyst material instead of Platinum or Rhodium, then material cost decreases, but Ruthenium is easily eluted by reverse current
Solution Approach 1:
The patent introduces a reverse current absorption body as an intermediary element that preferentially consumes the reverse current through oxidation reactions before it can reach and elute the Ruthenium catalyst. This protective intermediary allows the use of cost-effective Ruthenium while maintaining catalyst stability by blocking the harmful reverse current.
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 solution provides improved reverse current resistance with high discharge capacity, reduces material costs, and simplifies maintenance by allowing easy attachment and replacement of the reverse current absorption body, effectively addressing cathode degradation and operational complexities.
Implementation Method 1
the reverse current is consumed by an oxidation reaction of the reverse current absorption layer rather than the cathode
Implementation Method 2
the reverse current absorption body is formed from a sintered compact containing nickel
Data Source
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AI summary
Provided are an electrode for electrolysis having excellent durability against reverse current, and a method that enables production of the electrode for electrolysis at low cost. The electrode for electrolysis 130 includes a conductive substrate 132 on which a catalyst layer is formed, and a reverse current absorption body 134 that is coupled to the conductive substrate 132 in a detachable manner, wherein the reverse current absorption body 134 is formed from a sintered compact containing nickel. The method for producing the electrode for electrolysis 130 includes a sintered compact formation step of obtaining the sintered compact by sintering a raw material powder composed of any one of Raney nickel alloy particles containing nickel and an alkali-soluble metal element, metallic nickel particles, and a mixture of Raney nickel alloy particles and metallic nickel particles, and a coupling step of coupling the sintered compact to the conductive substrate 132.