Electrolysis Gas Generator With Segmented Electrolyte Pockets

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Solution Overview

Problem

Existing electrolysis product gas generators face inefficiencies due to leakage currents and sensitivity to unstable environments, which affect the accurate production and control of hydrogen and oxygen gas for hydrocarbon fuel combustion systems, particularly in applications like inland waterway cargo vessels.

Innovation Solution

The improved electrolysis product gas generator features a tank with multiple cell stacks comprising isolator/conductor, reactor, and spacer plate members, where the electrolyte is isolated in a pocket, reducing leakage currents and enhancing gas production control through optimized plate designs and configurations, such as notches and channels, allowing for efficient gas and electrolyte flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If electrolyte is exposed in traditional electrolysis cells, then electrolyte flow and gas release are facilitated, but leakage currents increase and production accuracy deteriorates

Engineering Contradiction:
Improvegas production accuracyVSAvoidleakage currents
Core Design Contradiction:
Measurement precisionVSLoss of energy

Solution Approach 1:

The electrolyte chamber is segmented into isolated pockets between spacer plate members, creating discrete electrolyte compartments. This segmentation prevents continuous electrolyte exposure and associated leakage currents while maintaining sufficient electrolyte contact with reactor plates for efficient gas production. Each pocket acts as an independent cell that controls electrolyte flow and prevents cross-contamination between adjacent cell stacks.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Spacer plate members with defined pockets act as intermediaries between the electrolyte supply and the reactor plates. These spacer plates mediate the electrolyte distribution, providing controlled contact zones that facilitate ionic conduction while preventing uncontrolled electrolyte exposure and leakage currents. The pocket structure serves as an intermediary mechanism that balances electrolyte access with leakage prevention.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If multiple cell stacks are arranged in parallel, then gas production capacity increases, but sensitivity to environmental instability increases

Engineering Contradiction:
Improvegas production capacityVSAvoidenvironmental stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

Multiple cell stacks are segmented into independent cell units, each with its own isolated electrolyte pockets and reactor plate assemblies. This segmentation allows parallel gas production while isolating each cell from environmental disturbances affecting other cells. The modular segmented structure enables scalable productivity without proportionally increasing system sensitivity to environmental instability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each cell stack is designed with localized electrolyte pockets and isolated reaction zones, creating uniform local conditions across multiple parallel stacks. This local quality consistency ensures that each cell operates independently with controlled electrolyte exposure, maintaining reliable and stable gas production across the entire multi-stack assembly regardless of environmental variations.

Inventive Principle:
Principle #3Local quality

3Ease of manufacture

If plate members are simplified in design, then manufacturing ease improves, but gas and electrolyte flow efficiency deteriorates

Engineering Contradiction:
Improveplate member fabricationVSAvoidgas and electrolyte flow efficiency
Core Design Contradiction:
Ease of manufactureVSProductivity

Solution Approach 1:

Each plate member is designed as a multi-functional component that simultaneously serves as a structural support, an electrolyte channel definition, a gas collection surface, and an electrical conductor. The reactor plates and spacer plates perform multiple functions within unified structures, eliminating the need for separate components and simplifying manufacturing while maintaining efficient gas and electrolyte flow pathways through integrated design features.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The design merges the functions of electrolyte distribution channels, gas collection surfaces, and structural support into unified plate member structures. By combining multiple functions into single components, the number of separate parts is reduced, manufacturing is simplified, and flow efficiency is maintained through integrated pathways that eliminate connection points and potential leakage zones between separate components.

Inventive Principle:
Principle #5Merging (Combining)

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 reduces leakage currents, improves gas production accuracy, and makes the system more robust and efficient, enabling on-demand hydrogen and oxygen gas generation suitable for large engines, with reduced sensitivity to environmental instability, thus enhancing fuel efficiency and emission reduction in hydrocarbon fuel combustion systems.

Implementation Method 1

Electrolysis of water is the decomposition of water (H 2 O) into oxygen (O 2 ) and hydrogen gas (H 2 ) due to an electric current being passed through the water

Methodology Applied
Scientific EffectElectrolysis: Electrolysis

Implementation Method 2

a conductive patch is arranged at a location so as to be in contact with the adjacent metal reactor plate of the cell stack and with the adjacent metal reactor plate of an adjacent cell stack

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3237653B1Electrolysis product gas generator, system and method for generating a product gas
Publication Date: 2018.11.14 EXINTEC BEHEER BV
  • EP3237653B1 patent drawingFigure 1a~1c
  • EP3237653B1 patent drawingFigure 2~3
  • EP3237653B1 patent drawingFigure 4a~4c

AI summary

The present invention relates to an electrolysis product gas generator for producing a product gas containing hydrogen gas and oxygen gas on the basis of electrolysis of an aqueous electrolyte. The product gas generator comprises a tank wherein a row of multiple cell stacks is provided, each cell stack, including in succession: -an isolator/ conductor plate member; -a first reactor plate member; -a spacer plate member; -a second reactor plate member. The isolator/conductor plate member has an isolator plate with a window or edge notch in which a conductive patch is arranged. The first and second reactor plate members each have an isolating frame surrounding a window and a metal reactor plate arranged in said window. The spacer plate member has an isolating frame defining a pocket in said spacer plate member, wherein the pocket is filled with aqueous electrolyte so that the electrolyte is in contact with the adjacent first and second metal reactor plates of the cell stack.