Periodic Lattice Flow-Through Electrodes for High Mass Transfer

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Solution Overview

Problem

Conventional flow-through electrodes (FTEs) in electrochemical reactors suffer from limited architectural control and engineering of microscale transport, leading to inefficient mass transport and high charge transfer resistance, which hinders their commercial viability and cost competitiveness.

Innovation Solution

The development of porous FTEs with periodic lattice structures, engineered for high active surface area, high conductivity, and high permeability, utilizing 3D printing to create deterministic structures that enhance inertial flow effects, thereby increasing mass transfer coefficients by 10×-100× compared to previous designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high permeability is increased to increase mass transfer rates, then mass transfer coefficient is improved, but hydrodynamically accessible surface area decreases

Engineering Contradiction:

Improvemass transfer coefficientVSAvoidhydrodynamically accessible surface area

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The patent changes the geometric parameters of the electrode structure by introducing periodic lattice patterns with specific pore sizes, shapes, and distributions. This allows independent optimization of permeability and surface area parameters that were previously coupled in conventional disordered structures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure combining conductive material (for electrochemical reactions) with strategically designed porous lattice structures (for fluid transport). This composite approach allows the conductive phase to provide surface area while the porous phase provides permeability, resolving the trade-off between these two properties.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional porous FTEs are used, then manufacturing is simple, but architectural control and microscale transport engineering are limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidarchitectural control

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating regions with different pore sizes, shapes, and connectivity within the electrode structure. Specific areas have optimized characteristics for different functions (e.g., high permeability regions for fluid distribution, high surface area regions for reactions), allowing microscale transport engineering while maintaining manufacturability through modular design.

Inventive Principle:

Principle #3Local quality

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 engineered FTEs achieve significantly improved mass transfer performance, enabling higher power densities and productivity in electrochemical reactors, making them more attractive for energy-efficient utilization and cost-effective solutions.

Implementation Method 1

engineered FTEs with periodic lattice structures that lead to an increase in the mass transfer including the mass correlation exponent as inertial flow effects dominate

Methodology Applied

Scientific EffectInertial flow: Inertia

Data Source

PatentUS20250334527A1Inertially enhanced mass transport using porous flow-through electrodes with periodic lattice structures

Publication Date: 2025.10.30 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

Disclosed are flow-through electrode devices and techniques for making flow-through electrodes. In one aspect, a flow through electrode apparatus comprises one or more fiber layers. Each fiber layer comprises a plurality of fibers oriented to be orthogonal to a flow direction of a fluid. The plurality of fibers are configured to cause an inertial flow of the fluid around the plurality of fibers at a first flow rate of the fluid.