Electrolyzer Buffer Element With Segmented Support Structure
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Solution Overview
Problem
Existing alkaline water electrolyzers in zero-gap configuration face challenges with achieving uniform and optimal electrical contact between electrodes while maintaining mechanical support and preventing plastic deformation of elastic elements under pressure differences.
Innovation Solution
The electrolyzer incorporates a buffer element with an elastic structure and a support structure comprising plastic or metallic rods, which act as end stops to absorb pressure differences and prevent plastic deformation, thereby enhancing electrical contact and mechanical support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic elements are used for uniform and large-area electrical contact, then electrical conductivity is improved, but mechanical support capability deteriorates
Solution Approach 1:
The support structure is segmented into multiple individual support elements (rods) distributed across the electrode surface. Each rod provides localized mechanical support while the collective array maintains uniform electrical contact pressure, resolving the contradiction between mechanical support and electrical conductivity.
Solution Approach 2:
The invention uses a composite structure combining elastic material (for electrical contact) and rigid material (for mechanical support). The support elements made of rigid material provide differential pressure support, while the elastic buffer element maintains electrical contact, creating a composite solution that satisfies both requirements.
2Strength
If rigid and stiff elements are used to support differential pressures, then mechanical support is improved, but electrical contact quality deteriorates
Solution Approach 1:
The support function is segmented from the electrical contact function. Rigid support elements handle differential pressure support, while a separate elastic buffer element ensures electrical contact quality. This functional segmentation allows each component to optimize its specific role without compromising the other.
Solution Approach 2:
The invention employs a composite structure where rigid support elements (for mechanical strength) are combined with an elastic buffer element (for electrical contact). This composite approach allows the system to simultaneously achieve differential pressure support and uniform electrical contact.
3Reliability
If elastic elements span large distances between support points, then uniform electrical contact is improved, but plastic deformation increases
Solution Approach 1:
The span between support points is segmented into smaller intervals by distributing multiple support elements across the electrode surface. This reduces the span length of each elastic buffer element, preventing plastic deformation while maintaining uniform electrical contact through the distributed support array.
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 solution reduces material consumption of nickel, prevents plastic deformation of elastic structures, and ensures improved electrical conductivity and mechanical support, thereby increasing the safety and efficiency of the electrolyzer.
Implementation Method 1
the elastic structure (31) and a support structure (32). The support structure comprises a plurality of support elements (321), for example rods, made of plastic or metallic or metal with plastic
Implementation Method 2
A conductive elastic body is disposed between one surface of the conductive partition opposite the one surface and one of the electrodes. One and the other of the electrodes form a conduction with the conductive partition at least through the protrusions and at least through the conductive elastic body
Data Source
Figure 1
Figure 1a
Figure 2~4
AI summary
The present invention relates to an electrolyzer comprising a first plate-shaped electrode (1), a second plate-shaped electrode (2), and an elastic buffer element (3), the buffer element (3) comprising an elastic structure (31) and a support structure (32), the support structure (32) comprising a plurality of support elements (321) made of plastic or metallic or metal with plastic, and a method for producing an electrolyzer according to the invention, characterized by the following method steps: - Producing the support structure (32), in particular the support elements (321), by injection molding, in particular from polysulfone (PSU), polypropylene random copolymer (PP-R), polyphenylene ether (PPE) or other suitable plastics; - Joining the support structure (32) into an elastic structure (31) building the elastic buffer element (3), wherein the elastic structure has preferably an undulating shape in cross-section and is preferably made of a nickel wire mesh; - arranging the resulting elastic buffer element (3) in front of the at least one electrode (1, 2), in particular between the housing (5), bipolar plate (51) or end plate (52), and at least one electrode (1, 2) in such a way that the support elements (321) are aligned perpendicular to the at least one electrode (1, 2).