Titanium Layered Electrode Sheets for Conductive Porous Support
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Solution Overview
Problem
Existing PEM electrolyzers and fuel cells face challenges in achieving optimal current flow, reactant flow, and resistance to pressure differentials while being economically viable, with current components like expanded metal sheets and non-wovens having poorly defined contact points and inefficient electrical conductivity.
Innovation Solution
A method for producing layered sheet structures from titanium or titanium alloys involves forming first and second sheet-like green parts with defined openings and channels, debinding, and sintering to create a strong, electrically conductive, and mechanically supportive structure for electrodes, eliminating the need for additional coatings like platinum or gold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expanded metal sheets or non-wovens are used as supporting layers, then mechanical support is provided, but electrical conductivity and contact point definition are poor
Solution Approach 1:
The patent employs a porous metal foam material as the supporting layer, which inherently provides both mechanical support and electrical conductivity. The controlled porosity (40-70 vol.-%) allows for reactant transport while the metal foam structure ensures continuous electrical pathways, eliminating the poor conductivity issue of expanded metal sheets and non-wovens.
Solution Approach 2:
The invention creates a composite structure by coating the porous metal foam supporting layer with a catalytically active layer containing platinum or iridium. This composite approach combines the mechanical support and conductivity of the metal foam with the catalytic functionality of the coating, achieving both structural integrity and electrical performance.
2Reliability
If additional coatings like platinum or gold are applied to improve electrical conductivity, then conductivity is enhanced, but production costs increase
Solution Approach 1:
The porous metal foam supporting layer inherently provides electrical conductivity without requiring additional conductive coatings. The material's own metallic structure serves the electrical conduction function, eliminating the need for expensive platinum or gold coatings while maintaining good electrical performance.
Solution Approach 2:
The controlled porosity of the metal foam (40-70 vol.-%) is optimized to balance mechanical strength, electrical conductivity, and reactant transport. This intrinsic property eliminates the need for additional conductive layers, reducing manufacturing complexity and cost.
3Productivity
If the porous transport layer has high porosity for good reactant transport, then mass transfer is improved, but mechanical strength decreases
Solution Approach 1:
The patent uses a porous metal foam material with controlled porosity (40-70 vol.-%) that provides both adequate reactant transport pathways and sufficient mechanical strength. The three-dimensional interconnected pore structure of the metal foam maintains structural integrity while allowing efficient gas and liquid transport.
Solution Approach 2:
The composite structure of porous metal foam supporting layer with catalytic coating provides mechanical strength through the foam framework while enabling reactant transport through the porous structure. The coating layer adds functional properties without compromising the underlying mechanical support.
4Reliability
If the supporting layer is made dense for high electrical conductivity, then electrical flow is improved, but reactant transport becomes inefficient
Solution Approach 1:
The porous metal foam structure provides an optimal balance between electrical conductivity and reactant transport. The interconnected pore network allows efficient gas and liquid flow while the metal framework ensures continuous electrical pathways. The porosity level (40-70 vol.-%) is specifically controlled to achieve both functions simultaneously.
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 method results in improved electrical conductivity and mechanical bonding strength, enhancing the efficiency and durability of PEM electrolyzers and fuel cells by ensuring uniform current flow and reactant transport, while reducing production costs.
Implementation Method 1
debinding the green part or green parts and sintering the stack to densify the green part or green parts contained therein and to simultaneously bond the metal sheet layers of the stack
Data Source
AI summary
A method for producing layered sheet structures from titanium or titanium alloy metal for use in or as electrodes of PEM-type electrolyzers or fuel cells. The method includes providing a first sheet-like green part with voids or open spaces, where first sheet-like green part is a green part of a first metal sheet layer. The method alternatively includes providing a first metal sheet layer comprising a metallic frame structure with voids or open spaces. The method further includes providing a second sheet-like green part, where second sheet-like green part is a green part of a second metal sheet layer, which is porous. The method alternatively includes providing a second metal sheet layer, which is porous. The method further includes forming a stack with a combination of the first and second sheet-like green part and the first and second metal sheet. The method further includes bonding the metal sheet layers.