PCB-Based AEM Electrolyser Design for Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current AEM electrolysers are expensive to manufacture at scale and lack customizability, which hinders their widespread adoption for green hydrogen production.
Innovation Solution
The use of Printed Circuit Board (PCB) plates instead of traditional metal plates for constructing AEM electrolysers, which allows for more cost-effective and customizable manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional metal plates are used for constructing AEM electrolysers, then structural strength and durability are maintained, but manufacturing costs increase and customizability is limited
Solution Approach 1:
The patent employs composite materials by combining PCB substrates with conductive coatings (such as copper or aluminum plating) to create electrode plates that achieve both cost reduction and sufficient structural strength. The PCB provides mechanical support while the conductive layer ensures electrical functionality, resolving the contradiction between low cost and strength.
Solution Approach 2:
The patent replaces traditional metal mechanical structures with PCB-based structures that integrate electrical conductivity and mechanical support in a single component. This substitution eliminates the need for separate metal plates and reduces manufacturing complexity, achieving lower costs while maintaining structural integrity through the PCB's rigid substrate design.
2Productivity
If traditional metal plates are used for constructing AEM electrolysers, then structural durability is maintained, but manufacturing complexity and scale production difficulty increase
Solution Approach 1:
The patent segments the electrolyser structure into modular PCB-based units that can be independently manufactured and assembled. Each PCB plate functions as a complete electrode assembly with integrated flow channels and electrical connections, enabling standardized mass production while simplifying the overall manufacturing process through modular architecture.
Solution Approach 2:
The PCB plates serve multiple functions simultaneously: structural support, electrical conduction, fluid distribution through integrated channels, and electrode functionality. This multi-functionality eliminates the need for separate components, reducing manufacturing complexity and enabling efficient scale production through standardized processes.
3Adaptability or versatility
If PCB plates are used instead of traditional metal plates, then manufacturing costs are reduced and customizability is improved, but structural strength may be compromised
Solution Approach 1:
The patent applies local quality by providing conductive coatings only in specific regions where electrical conductivity is needed, while maintaining the PCB's structural integrity in other areas. The conductive plating is applied to contact surfaces and current collection areas, allowing customization of electrical properties without compromising overall structural strength.
Solution Approach 2:
The PCB structure combines the mechanical strength of the substrate material (such as FR-4 or similar composite boards) with conductive surface layers, creating a composite structure that achieves both customizability through PCB design flexibility and sufficient structural strength through the substrate's rigid framework.
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 PCB-based AEM electrolysers offer significant reductions in manufacturing costs per unit volume, improved customizability, and a more compact, lightweight design, enhancing their efficiency and scalability for hydrogen production.
Implementation Method 1
An anion exchange membrane (AEM) is a membrane generally made from ionomers which can conduct anions (e.g. OH-ions in a hydroxide anion exchange membrane) across its membrane
Implementation Method 2
An electrolyser is a device in which electrolysis occurs, where an electrolyte is decomposed as part of a chemical reaction at electrodes, driven by an electric current passed through the electrolyte via the electrodes
Implementation Method 3
AEM electrolysers may have a catalyst containing layer or catalyst present somewhere on either side of the AEM
Data Source
AI summary
An electrolyser (200) comprising: a cathode structure comprising a first PCB plate (202) and an electrically conductive substrate (220); an anode structure comprising a second PCB plate (204) and an electrically conductive substrate (220); an anion exchange membrane (218) located between the cathode structure (202) and the anode structure (204); two transport layers, (214, 216), one transport layer (216) disposed between the anode structure (204) and the anion exchange membrane (218) and one transport layer (214) disposed between the cathode structure (202) and the anion exchange membrane (218); and at least one fluid path to supply an electrolyte to the electrolyser (200).