Polymeric Membrane Penetration into Porous Metal Substrate
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Solution Overview
Problem
The production of alkaline electrolysers and fuel cells is hindered by the complexity of assembling porous gas diffusion layers with membranes, leading to inefficiencies and reduced operational temperatures due to the use of reinforcing carrier webs, which result in thicker membranes and decreased performance.
Innovation Solution
A method for producing a single assembly of a porous metallic gas diffusion substrate and a polymeric separator membrane without a reinforcing web, where the membrane penetrates into the substrate, enhancing stability and contact, allowing for higher operational temperatures and reduced thickness, thus improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a reinforcing web or fabric is incorporated in the polymeric separator membrane to ensure dimensional stability, then the membrane stability is improved, but the membrane thickness increases and efficiency decreases
Solution Approach 1:
The invention removes the reinforcing web or fabric from the polymeric separator membrane construction. Instead of incorporating a separate reinforcing layer, the patent uses the porous metallic gas diffusion substrate itself to provide the necessary mechanical support and dimensional stability, thereby eliminating the need for additional thickness from reinforcing elements.
Solution Approach 2:
The porous metallic gas diffusion substrate serves dual functions: it acts as both the structural support (replacing the reinforcing web) and as the functional gas diffusion layer. This multi-functionality eliminates the need for separate reinforcing elements while maintaining both mechanical stability and gas diffusion performance.
2Manufacturing precision
If a reinforcing carrier web is used in the membrane to achieve flatness during assembly, then the assembly flatness is improved, but the membrane thickness increases and machine footprint increases
Solution Approach 1:
The invention eliminates the reinforcing carrier web from the membrane structure, removing the source of additional thickness that leads to increased machine footprint. The porous metallic substrate provides inherent flatness without requiring additional reinforcing layers.
Solution Approach 2:
The invention uses a composite structure where the polymeric separator membrane is integrated directly with the porous metallic gas diffusion substrate. This composite construction provides both the necessary flatness for assembly and the mechanical strength without requiring separate reinforcing carrier webs, thereby reducing overall thickness and machine footprint.
3Stability of the object's composition
If a polymeric fabric is used as reinforcing carrier web, then the membrane stability is improved, but the maximum operational temperature is limited
Solution Approach 1:
The invention removes the polymeric fabric reinforcing carrier web that limits operational temperature. By using the porous metallic gas diffusion substrate as the sole structural support, the system can operate at higher temperatures without being constrained by the thermal stability limits of polymeric fabrics.
Solution Approach 2:
The invention changes the material parameter of the reinforcing structure from polymeric fabric to porous metallic substrate. This material substitution enables the system to withstand higher operational temperatures while maintaining the necessary mechanical stability and dimensional integrity of the membrane assembly.
4Stability of the object's composition
If the membrane is made thicker to incorporate reinforcing web, then the dimensional stability is improved, but the efficiency of electrolyser or fuel cell decreases
Solution Approach 1:
The invention extracts the reinforcing web from the membrane construction, eliminating the additional thickness it contributes. The porous metallic gas diffusion substrate provides the necessary dimensional stability without the extra thickness, thereby maintaining shorter ion transport paths and higher cell efficiency.
Solution Approach 2:
The integrated composite structure of polymeric separator membrane and porous metallic gas diffusion substrate provides dimensional stability through the metallic substrate's inherent properties rather than through additional polymeric reinforcing layers. This eliminates unnecessary thickness while maintaining stability, thereby preserving electrode contact quality and ion transport efficiency.
5Strength
If multiple coating processes are used to produce reinforced separator membrane, then the membrane strength is improved, but the production complexity increases
Solution Approach 1:
The invention removes the requirement for multiple coating processes by eliminating the need for separate reinforcing web application steps. The porous metallic gas diffusion substrate provides inherent mechanical strength without requiring additional coating operations, thereby simplifying the production process.
Solution Approach 2:
The invention merges the functions of the separator membrane and the reinforcing structure into a single integrated construction. The porous metallic gas diffusion substrate simultaneously provides mechanical support and serves as the functional gas diffusion layer, eliminating the need for separate reinforcing web coating processes and simplifying manufacturing.
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 approach results in increased efficiency, reduced voltage drop, and extended operational life by ensuring intimate contact between the membrane and electrodes, while allowing for higher operational temperatures and a reduced machine footprint.
Implementation Method 1
The polymeric separator membrane is penetrating into at least a top portion of the porous metallic gas diffusion substrate
Data Source
Figure 1~3
AI summary
The invention relates to an assembly of a porous metallic gas diffusion substrate and a polymeric separator membrane for use in an alkaline electrolyser or alkaline fuel cell. The polymeric separator membrane of the assembly comprises inorganic hydrophilic particulates dispersed in an organic polymeric binder. The polymeric separator membrane is gas tight when filled with electrolyte. The polymeric separator membrane is penetrating into at least a top portion of the porous metallic gas diffusion substrate. Also disclosed is a method to produce such an assembly via coating a paste on a porous metallic gas diffusion substrate.