Isolated Bipolar Plate Assembly for Hermetic Electrolysis Cells
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Solution Overview
Problem
Existing electrochemical cells and stacks face challenges with electrical isolation, high cell pitch due to shorting through liquid containing plenums, complex supply chains, limited manufacturing speed, hydrogen and water leakage, material scrap, and alignment issues during stacking.
Innovation Solution
Innovative designs and materials for bipolar plates, seals, and assembly methods that provide hermetic sealing, precise alignment, and built-in compliance, enabling high-speed manufacturing and improved electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid containing plenums are used in electrochemical stacks, then manufacturing and assembly is simplified, but electrical isolation between cells is compromised causing shorting
Solution Approach 1:
The bipolar plate is segmented into distinct regions: a conductive region for electrical connection and a non-conductive region for electrical isolation. This segmentation allows the plate to simultaneously provide both electrical conductivity where needed and insulation where needed, preventing shorting between cells while maintaining manufacturing simplicity
Solution Approach 2:
Different regions of the bipolar plate are assigned different electrical properties. The conductive region has high electrical conductivity for current flow, while the non-conductive region has low electrical conductivity for isolation. This local differentiation of material properties resolves the contradiction between needing electrical connection and electrical isolation in the same component
2Productivity
If cell pitch is reduced to increase stack density, then manufacturing efficiency improves, but electrical shorting through liquid plenums increases
Solution Approach 1:
The bipolar plate is divided into conductive and non-conductive regions, creating an electrical isolation barrier that prevents shorting even when cells are packed closely together. This allows reduced cell pitch without compromising electrical isolation
Solution Approach 2:
The non-conductive region acts as an intermediary barrier between the liquid plenums of adjacent cells. It blocks the conductive path through the liquid, preventing electrical shorting while allowing the cells to be positioned closer together
3Ease of manufacture
If conventional sealing methods are used, then assembly is simpler, but hydrogen and water leakage occurs
Solution Approach 1:
The sealing function is merged into the bipolar plate structure itself through the non-conductive region, which provides both electrical isolation and sealing. This integration eliminates the need for separate sealing components while preventing hydrogen and water leakage
Solution Approach 2:
The bipolar plate is designed to perform multiple functions simultaneously: electrical connection in the conductive region, electrical isolation in the non-conductive region, and sealing against hydrogen and water leakage. This multi-functionality resolves the contradiction between assembly simplicity and sealing performance
4Reliability
If complex multi-component assemblies are used, then electrical isolation and sealing are improved, but manufacturing speed decreases
Solution Approach 1:
Multiple functions (electrical connection, electrical isolation, sealing) are merged into a single bipolar plate component. This eliminates the need for separate components for each function, reducing assembly steps and increasing manufacturing speed while maintaining reliability
Solution Approach 2:
The bipolar plate is designed as a multi-functional component that simultaneously provides electrical connection, electrical isolation, and sealing. This universality reduces the total component count and simplifies assembly, thereby increasing manufacturing speed without compromising performance
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
Enhances electrical isolation, reduces cell pitch requirements, minimizes leakage, and facilitates faster, more reliable assembly of electrochemical cells and stacks.
Implementation Method 1
the liquid plenum features of the sub-gasket and water seal are dimensioned smaller than corresponding liquid plenum features of the bipolar plate assembly to provide electrical isolation for at least three edges of the liquid plenum
Implementation Method 2
The thermoplastic materials for these components are selected to have compatible properties to allow homogeneous mixing at the interface during hot-melt processing
Implementation Method 3
the thermoplastic material is UV cross-linkable to enhance high temperature mechanical properties in-situ
Data Source
AI summary
The present application relates to components for use in an electrolysis cell and/or stack comprising features, geometry, and materials to overcome prior art limitations related to cell electrical isolation, fluid sealing, and high speed manufacturing. The electrolysis cell comprises a membrane, an anode, a cathode, an anode flow field, a cathode flow field, and a bipolar plate assembly comprising an embedded hydrogen seal and both conductive and non-conductive areas. The components are cut using two-dimensional patterns from substantially flat raw materials capable of being sourced in roll form. These substantially two-dimensional components are processed to create a fully unitized, three-dimensional electrolysis cell with a hermetically sealed cathode chamber.