Gas-Permeable Conductive Plate with Layered Pores for Electrolyzers
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Solution Overview
Problem
Existing porous transport layers in electrolyzers face a contradiction between maximizing catalyst interface and fluid transport, as small pores enhance catalyst contact but hinder mass transfer, while large pores improve fluid flow but reduce interface.
Innovation Solution
A gas-permeable electronically conductive plate with recesses, such as through-holes, dimples, or grooves, allows for increased fluid transport without compromising electronic contact and mechanical stability, featuring varying pore sizes and shapes to optimize both aspects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If small pores are used to maximize catalyst interface contact, then electronic contact and catalyst utilization are improved, but mass transfer and fluid transport are hindered
Solution Approach 1:
The porous transport layer is segmented into multiple layers with different pore size characteristics. The first layer (adjacent to bipolar plate) has larger pores for fluid transport, while the second layer (adjacent to catalyst layer) has smaller pores for catalyst contact. This segmentation allows each layer to optimize for its specific function, resolving the contradiction between fluid transport and catalyst interface contact.
Solution Approach 2:
Different regions of the porous transport layer are assigned different pore size characteristics tailored to their specific functions. The region near the bipolar plate has larger pores to facilitate fluid transport, while the region near the catalyst layer has smaller pores to maximize catalyst contact. This local differentiation allows simultaneous optimization of both mass transfer and electronic contact.
2Productivity
If large pores are used to maximize fluid transport, then mass transfer and pressure drop are improved, but catalyst interface contact is reduced
Solution Approach 1:
The porous transport layer is divided into functional segments: a first layer with larger pores for fluid transport near the bipolar plate, and a second layer with smaller pores for catalyst contact near the catalyst layer. This segmentation enables each segment to optimize for its primary function without compromising the other.
Solution Approach 2:
The pore size characteristics are locally optimized for different regions. Larger pores are located where fluid transport is critical (near bipolar plate), while smaller pores are located where catalyst contact is critical (near catalyst layer). This spatial differentiation resolves the contradiction between fluid transport efficiency and catalyst interface contact.
3Stress or pressure
If pore size is increased to reduce pressure drop, then fluid transport is improved, but mechanical stability and electronic contact are compromised
Solution Approach 1:
The porous transport layer is segmented into a first layer (larger pores, lower pressure drop) and second layer (smaller pores, higher mechanical stability). The first layer reduces pressure drop for fluid transport, while the second layer maintains mechanical stability and electronic contact, resolving the contradiction between pressure drop and reliability.
Solution Approach 2:
Different regions have different pore size characteristics optimized for their local requirements. The first layer near the bipolar plate has larger pores to minimize pressure drop, while the second layer near the catalyst layer has smaller pores to maintain mechanical stability and electronic conductivity. This local optimization resolves the contradiction between pressure drop and reliability.
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 facilitates efficient fluid transport and maintains catalyst contact, reducing pressure drop and enhancing reactant access to the catalyst layer, improving electrolyzer performance and yield.
Implementation Method 1
porous transport layers provide transport passages for liquid educts like water and gaseous products like oxygen and hydrogen
Implementation Method 2
required to have a low pressure drop to facilitate the fluid transport
Implementation Method 3
porous transport layers have to provide electronic contact to the bipolar plate adjacent a first surface of the porous transport layer and to the catalyst layer adjacent the second surface
Data Source
AI summary
Described are a gas-permeable electronically conductive plate for use as porous transport layer for an electrolyzer and a process for preparing said gas-permeable electronically conductive plate. a building unit for an electrolyzer, and an electrolyzer.