Multi-Layer Electrode for High Differential Pressure

Solution Overview

Problem

Electrodes in high-pressure electrochemical cells face challenges in maintaining membrane integrity under differential pressure, leading to potential bursting or damage, while also requiring efficient material flow, which is compromised by porosity adjustments that affect both stability and efficiency.

Innovation Solution

The electrode is constructed with multiple layers of varying pore sizes, where a smaller pore size layer contacts the membrane for stability and larger pore size layers provide mechanical stability and facilitate material flow, ensuring the electrode can withstand high pressures without membrane damage and maintain efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the electrode porosity is increased to facilitate material flow, then the efficiency of material transport improves, but the mechanical stability and resistance to high pressure decrease

Engineering Contradiction:

Improvematerial flow efficiencyVSAvoidmechanical stability

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The electrode is divided into multiple layers with different pore sizes. The first layer has larger pores for efficient material flow, while the second layer has smaller pores for mechanical stability and pressure resistance. This segmentation allows each layer to optimize for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the electrode have different pore sizes tailored to their specific functional requirements. The region closer to the membrane (second layer) has smaller pores for stability, while the outer region (first layer) has larger pores for flow efficiency.

Inventive Principle:

Principle #3Local quality

2Reliability

If the electrode porosity is decreased to improve mechanical stability under high pressure, then the resistance to bursting improves, but the material flow efficiency decreases

Engineering Contradiction:

Improvemembrane integrityVSAvoidmaterial flow efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The electrode is divided into multiple layers with different pore sizes. The first layer has larger pores for efficient material flow, while the second layer has smaller pores for mechanical stability and pressure resistance. This segmentation allows each layer to optimize for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the electrode have different pore sizes tailored to their specific functional requirements. The region closer to the membrane (second layer) has smaller pores for stability, while the outer region (first layer) has larger pores for flow efficiency.

Inventive Principle:

Principle #3Local quality

3Device complexity

If a single-layer electrode design is used, then the device complexity is reduced, but the ability to simultaneously achieve high pressure resistance and efficient material flow is compromised

Engineering Contradiction:

Improveelectrode structureVSAvoidperformance under differential pressure

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The electrode is divided into multiple layers with different pore sizes. The first layer has larger pores for efficient material flow, while the second layer has smaller pores for mechanical stability and pressure resistance. This segmentation allows each layer to optimize for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode uses a composite structure with layers of different pore sizes, combining the advantages of high porosity (for flow) and low porosity (for stability) in a single integrated component.

Inventive Principle:

Principle #40Composite materials

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 multi-layered electrode design effectively prevents membrane bursting and ensures efficient material flow, allowing for operation at high pressures without compromising cell efficiency, with the contact layer being thin and highly resistant to enable gas and fluid flow, and the supporting layers providing necessary stability.

Implementation Method 1

The porous electrode produced by sintering is used in the cell

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

which are catalytically active towards the electrochemical reactions to be performed

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

The porous electrode produced by sintering is used in the cell

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS8152974B2Electrode for electrochemical cell operating with high differential pressure difference, procedure for the manufacturing of such electrode and electrochemical cell for the use of such electrode

Publication Date: 2012.04.10 THALESNANO ZRT

AI summary

The invention relates to a porous electrode used in an electrochemical cell, containing a carrier and/or catalytic agent, which is characterized by that it consists of two or more layers with different average pore sizes, out of which layers the contact layer with the smallest average pore size is in contact with the membrane, and one or more supporting layers with a greater average pore size are linked to the other side of this contact layer. Furthermore, the invention relates to a procedure for the manufacturing of such electrodes and to electrochemical cells containing such electrodes.