DESC:FIELD OF THE INVENTION
The present invention generally relates to the field of hydrogen production technologies. More particularly, the present invention relates to a cell assembly for high-efficient production of hydrogen ( H_2 ) through electrolysis comprising at least one electrolyzer cell configured with a sandwich assembly and a multi-chamber assembly, and a method thereof.
BACKGROUND OF THE INVENTION
This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Hydrogen production technologies have gained significant attention in recent years as the world moves toward sustainable energy solutions. Water electrolysis represents one of the most promising methods for producing hydrogen as a clean energy carrier, involving the splitting of water molecules into hydrogen and oxygen using electrical energy. As global climate concerns escalate, the need for sustainable energy sources has intensified, positioning hydrogen as a key energy carrier of the future. Water electrolysis, in particular, has emerged as a focal point in research and development for achieving carbon neutrality targets by 2050. Hydrogen produced via electrolysis can be used in various applications such as fuel cells and green industrial processes. However, efficient hydrogen ( H_2 ) generation through electrolysis remains a widely recognized challenge. In conventional electrolysis systems, hydrogen ( H_2 ) and oxygen ( O_2 ) gases are generated simultaneously, which not only necessitates complex gas separation infrastructure but also poses safety concerns due to possible gas mixing. Furthermore, the conventional electrolysis systems often rely on continuous heating of the electrolyte, leading to energy inefficiencies and thermal management issues.
Existing solutions, such as the Electrochemical-Thermally Activated Chemical (E-TAC) process, attempt to overcome the limitations of conventional electrolysis by temporally separating H_2 and O_2 evolution. However, these systems necessitate that one or more electrolyzer cells remain filled with heated electrolyte and rely on rapid and repeated heating and cooling cycles of the anode. This imposes significant thermal management challenges, increases the risk of material degradation, and adds to operational complexity, thereby raising critical engineering challenges to scalability, stability, and long-term efficiency of a cell assembly.
While industrial applications such as chlorine, sodium hydroxide, and aluminum production have laid the groundwork for electrolytic process scaling, existing electrolysis technologies still require major innovation to meet emerging demands in efficiency, cost-effectiveness, and integration with renewable energy sources. However, widespread adoption of existing electrolysis technologies is constrained by several drawbacks. These include substantial power losses due to the over-potential associated with the oxygen evolution reaction (OER), high costs of components used in both the hydrogen and oxygen compartments, and limitations in the pressure at which hydrogen can be produced.
One patent application US10633661 discloses an electrochemical cell for water electrolysis comprising a cathode, an anode, and a separator positioned between the cathode and anode. The system operates with simultaneous evolution of hydrogen and oxygen gases, requiring complex separation mechanisms and presenting safety risks due to potential gas mixing. Additionally, the system lacks efficient thermal management, resulting in energy losses from heating the entire electrolyte volume rather than targeted heating of reaction sites.
Another patent application US2020/0332435 describes a method for hydrogen production using a multi-step electrolysis process with separate hydrogen and oxygen evolution phases. However, the system requires complete heating and cooling cycles of the entire cell assembly between production phases, leading to significant energy inefficiencies, extended cycle times, and accelerated material degradation from thermal cycling. The system also lacks localized heating capabilities, resulting in unnecessary thermal load on non-reactive components.
Keeping in view the challenges associated with state of the art, there is a need for a cell assembly for high-efficient production of hydrogen through electrolysis that enables spatial and temporal separation of hydrogen and oxygen evolution while implementing localized heating of the anode electrode. Such a system would eliminate the need for complex gas separation infrastructure, improve safety by preventing gas mixing, reduce energy consumption through targeted heating, and enhance overall system efficiency and durability.
OBJECTIVE OF THE INVENTION
The primary objective of the present invention is to provide a cell assembly for hydrogen production through electrolysis that enables spatial and temporal separation of hydrogen and oxygen evolution, thereby eliminating the need for complex gas separation infrastructure and reducing safety risks associated with gas mixing.
Another objective of the present invention is to provide localized heating of the anode electrode through an integrated heating member, which may minimize energy consumption by avoiding unnecessary heating of the entire electrolyte volume and surrounding cell components.
Another objective of the present invention is to provide improved thermal management through a compact sandwich assembly design that may facilitate effective heat dissipation and reduce thermal stress on system components.
Another objective of the present invention is to provide enhanced operational efficiency by eliminating the need for full system cooling between hydrogen and oxygen generation cycles, thereby reducing cycle times and improving overall process performance.
Another objective of the present invention is to provide a modular and scalable system architecture that may be configured in multiple forms to optimize space utilization within cell structures.
Another objective of the present invention is to provide controlled fluid exchange through a multi-chamber assembly with integrated valve lines and sensors, which may enable precise management of electrolyte flow, temperature regulation, and gas handling operations.
Another objective of the present invention is to provide high-purity hydrogen generation with improved theoretical efficiencies through selective and temporally separated electrochemical reactions.
Another objective of the present invention is to provide reduced material degradation and extended operational life by minimizing rapid heating and cooling cycles that are typically required in conventional electrolysis systems.
Another objective of the present invention is to provide simplified system operation through automated control algorithms that may manage valve operations, heating, and power supply based on real-time sensor feedback.
Yet another objective of the present invention is to provide cost-effective hydrogen production by reducing the complexity of gas separation equipment and minimizing energy losses associated with simultaneous gas evolution processes
Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION
The present invention relates to a cell assembly and a method for high-efficient production of hydrogen ( H_2 ) through electrolysis. The cell assembly comprises at least one electrolyzer cell configured with a sandwich assembly and a multi-chamber assembly operatively connected to the at least one electrolyzer cell. The sandwich assembly may include an anode electrode, a cathode electrode, a spacer positioned between the anode and cathode electrodes to maintain a constant gap, a heating member disposed behind the anode electrode for localized heating H_2 O_2 O_2 H_2 O_2 O_2 H_2associated fluid storage units, and an intermediate holding unit. In an exemplary embodiment, the associated fluid storage units may include one of H_2 O_2 wherein the heating member is in thermal contact with the anode electrode, an insulating sheet positioned adjacent to the heating member opposite to the anode electrode wherein the insulating sheet thermally isolates the heating member from surrounding components, and an electrically conducting metal tab configured to provide electrical bias by connecting the anode and cathode electrodes at respective edges wherein the electrically conducting metal tab is in electrical communication with the power supply. In an embodiment, the sandwich assembly enables spatial and temporal separation of hydrogen ( H_2 ) and oxygen ( H_2,O_2 O_2 H_2 ) evolution by arresting O_2 generation during H_2 H_2production. Furthermore, the O_2 evolution may be suppressed by oxidizing the anode electrode during hydrogen generation at ambient tH_2 (Ni(OH)_2 )(NiOOH)emperature, followed by releasing O_2 O_2upon heating the oxidized anode electrode. This spatial and temporal separation prevents gas mixing and enhances system safety and efficiency. The sandwich assembly is further designed to 2-120mVbe compact, limit unnecessary heating, and facilitate effective heat dissipation.
BRIEF DESCRIPTION OF FIGURES
The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
Figure 1 illustrates a sandwich electrode assembly that comprises a cathode sheet, spacer, anode sheet, heating element, and insulating sheet which are arranged in a compact layered configuration for efficient electrolysis operations;
Figure 2 illustrates a multi-chamber cell assembly system that shows two electrolyzer cells connected through valve lines, control systems, and a buffer chamber for coordinated hydrogen and oxygen production cycles;
Figure 3(a) illustrates a side view of the cell stack that shows the layered electrode assembly configuration;
Figure 3(b) illustrates a cell stack assembly view that demonstrates the compact electrode arrangement;
Figure 3(c) illustrates an exploded view of the cell stack that shows the individual components and their assembly relationship;
Figure 3(d) illustrates an electrode assembly transverse view that shows the cross-sectional arrangement of the sandwich structure components;
Figure 4 illustrates the multi-chamber cell assembly connections that demonstrate the fluid flow paths, valve systems, and control mechanisms between the electrolyzer cells and associated storage units.
DETAILED DESCRIPTION
The following description describes various features and functions of the disclosed system. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.
Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purposes only and not for the purpose of limiting the invention.
It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.
It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, steps or components but does not preclude the presence or addition of one or more other features, steps, components or groups thereof. The equations used in the specification are only for computation purpose.
Accordingly, the present invention relates to the field of hydrogen production technologies and provides a cell assembly for high-efficient production of hydrogen (H_2) through electrolysis that addresses the limitations of conventional electrolysis systems. The present invention overcomes the challenges associated with simultaneous gas generation, complex gas separation infrastructure, safety concerns due to gas mixing, energy inefficiencies from continuous electrolyte heating, and thermal management issues.
In an embodiment, the cell assembly (100) for hydrogen (H_2) production through electrolysis comprises:
(A) At least one electrolyzer cell (102): The electrolyzer cell (102) configured with a sandwich assembly (104), wherein the sandwich assembly (104) includes an anode electrode (106) operatively connected to a power supply (108) through electrical connections (110), a cathode electrode (112) also operatively connected to the power supply (108) through the electrical connections (110), a spacer (114) positioned between the anode electrode (106) and the cathode electrode (112) to maintain a constant gap there between and facilitate proper electrolyte flow, a heating member (116) disposed behind the anode electrode (106) for providing localized heating wherein the heating member (116) is in thermal contact with the anode electrode (106) and operatively connected to a control system (118), an insulating sheet (120) positioned adjacent to the heating member (116) opposite to the anode electrode (106) wherein the insulating sheet (120) thermally isolates the heating member (116) from surrounding components to prevent heat loss, and an electrically conducting metal tab (122) configured to provide electrical bias by connecting the anode electrode (106) and the cathode electrode (112) at respective edges thereof wherein the electrically conducting metal tab (122) is in electrical communication with the power supply (108).
The at least one electrolyzer cell (102) is configured with a sandwich assembly (104) that includes an anode electrode (106), a cathode electrode (112), a spacer (114) positioned between the anode and cathode electrodes to maintain a constant gap, a heating member (116) disposed behind the anode electrode for localized heating, an insulating sheet (120) positioned adjacent to the heating member opposite to the anode electrode, and an electrically conducting metal tab (122). The sandwich assembly enables spatial and temporal separation of hydrogen and oxygen evolution by arresting O2 generation during H2 production through oxidation of the anode electrode during hydrogen generation at ambient temperature, followed by releasing O2 upon heating the oxidized anode electrode. In an embodiment, the one or more electrolyzer cells (102) may be purged in a cyclic manner using a non-reactive gas from the non-reactive gas storage (158) following evolution of H_2 and O_2. The non-reactive gas may operate in a closed-loop configuration as a separating medium between cold electrolyte and hot electrolyte retained in the one or more electrolyzer cells (102) at a given time, thereby minimizing gas loss and eliminating the need for frequent refilling.
The sandwich assembly (104) may be configured to enable spatial and temporal separation of hydrogen (H_2) and oxygen (O_2) evolution by arresting O_2 generation during H_2 production through oxidation of the anode electrode (106) during hydrogen generation at ambient temperature, followed by releasing O_2 upon heating the oxidized anode electrode (106). This spatial and temporal separation prevents gas mixing and enhances system safety and efficiency by eliminating the need for complex gas separation infrastructure. The sandwich assembly (104) design may be configured in multiple forms including parallel plates or in a form of a spiral jelly roll to increase space utilization within a cell structure. This flexible design approach allows for optimization of surface area and electrolyte contact while maintaining compact dimensions.
(i) The anode electrode (106) is operatively connected to a power supply (108) through electrical connections (110). The anode electrode comprises nickel hydroxide (Ni(OH)2) configured to convert into nickel oxyhydroxide (NiOOH) during the electrolysis process. This conversion enables the temporal separation of gas evolution by storing oxygen in the electrode material during the hydrogen generation phase.
(ii) The cathode electrode (112) is operatively connected to the power supply (108) through the electrical connections (110). During the hydrogen generation phase, H2 is produced at the cathode electrode under ambient conditions while O2 evolution is arrested by oxidizing the redox-active anode electrode.
(iii) The spacer (114) is positioned between the anode electrode (106) and the cathode electrode (112) to maintain a constant gap there between and facilitate proper electrolyte flow. This consistent electrode gap ensures uniform current distribution and efficient electrochemical reactions throughout the cell.
(iv) The heating member (116) is disposed behind the anode electrode (106) for providing localized heating wherein the heating member is in thermal contact with the anode electrode and operatively connected to a control system (118). The heating member is configured to provide localized heating to the anode electrode without heating the entire electrolyte volume, thereby reducing energy consumption and improving thermal efficiency. This localized heating approach minimizes energy consumption by avoiding unnecessary heating of the entire electrolyte volume and surrounding cell components.
(v) The control system (118) may be interfaced via the one or more terminals (148) to manage operation of the valve lines (136), heating member (116), and power supply (108) through programmable logic controllers or microprocessor-based systems. The control system (118) may implement automated sequences for gas production, fluid transfer, and thermal management based on real-time feedback from the sensors (144).
(vi) The insulating sheet (120) is positioned adjacent to the heating member (116) opposite to the anode electrode (106) wherein the insulating sheet thermally isolates the heating member from surrounding components to prevent heat loss. This thermal isolation ensures that heat is directed efficiently toward the anode electrode rather than being dissipated to other cell components.
(vii)The electrically conducting metal tab (122) is configured to provide electrical bias by connecting the anode electrode (106) and the cathode electrode (112) at respective edges thereof wherein the electrically conducting metal tab is in electrical communication with the power supply (108). This connection enables appropriate electrical biasing required for the electrochemical reactions.
(B) The multi-chamber assembly (124) is operatively connected to the at least one electrolyzer cell (102) through fluid connections (126). The multi-chamber assembly includes an electrolyte (128) that may be selected from alkali solutions including potassium hydroxide (KOH) or sodium hydroxide (NaOH). The multi-chamber assembly with integrated valve lines and sensors enables precise management of electrolyte flow, temperature regulation, and gas handling operations.
The cell-connection assembly (130) has at least one inlet (132) and at least one outlet (134) fluidically connected to the electrolyzer cell (102). These inlets and outlets allow for gas release and electrolyte exchange between different chambers of the system.
The one or more valve lines (136) include two-way solenoid valves (138) and three-way valves (140) wherein the valve lines fluidically connect the at least one electrolyzer cell (102) to an intermediate holding unit (142) and enable controlled fluid transfer. The valve lines are configured to fluidically connect the electrolyzer cells to each other and to the intermediate holding unit, enabling coordinated operation of multiple cells in a system configuration. Certain valve lines may incorporate heat exchangers (160) configured to regulate temperature of circulating electrolyte based on signals received from the one or more sensors
One or more sensors (144) configured to monitor operating conditions within the cell assembly (100) including temperature, pressure, and electrolyte levels, the control system (118) operatively connected to the one or more sensors (144) and configured to manage operation of the valve lines (136), heating member (116), and power supply (108) through automated control algorithms, the electrical connections (110) configured to link the anode electrode (106) and the cathode electrode (112) to the power supply (108), the power supply (108) electrically connected to the anode electrode (106) and the cathode electrode (112) through the electrical connections (110), one or more openings (146) configured to allow gas release and electrolyte exchange between different chambers, one or more terminals (148) configured to interface the control system (118) with the valve lines (136) and the power supply (108), associated fluid storage units (150) including at least one of H_2 gas storage (152), O_2 gas storage (154), water reservoir (156), and non-reactive gas storage (158) wherein each storage unit is fluidically connected to the multi-chamber assembly (124), and the intermediate holding unit (142) that functions as a buffer chamber acting as a temporary storage and regulating unit for fluids during the electrolysis process.
In an embodiment, the present invention also relates to a method for hydrogen (H_2) production through electrolysis. The method comprises the following steps:
pumping an electrolyte (128) into one or more electrolyzer cells (102) in absence of an electrical bias through the cell-connection assembly (130) and valve lines (136);
locally heating the electrolyte (128) using a heating member (116) positioned at an anode electrode (106) of a first cell from the one or more electrolyzer cells (102) under control of the control system (118);
applying the electrical bias to the first cell through the power supply (108) and electrical connections (110) to initiate electrochemical reduction of the electrolyte (128), generation of hydroxide ions, oxidation of the anode electrode (106), and evolution of H_2 gas at a cathode electrode (112);
collecting the evolved H_2 gas through the openings (146) and directing it to the H_2 gas storage (152) via the associated fluid storage units (150);
converting nickel hydroxide (Ni(OH)2) into nickel oxyhydroxide (NiOOH) at the anode electrode (106) to arrest O_2 evolution at ambient temperature;
transferring the electrolyte (128) from the first cell to the intermediate holding unit (142) through the valve lines (136);
purging the first cell with a non-reactive gas from the non-reactive gas storage (158) through the intermediate holding unit (142);
pumping the non-reactive gas from the first cell into a second cell through the valve lines (136);
pumping hot electrolyte (128) from the second cell into the first cell to cause thermal regeneration of the oxidized anode electrode (106);
releasing O_2 gas without application of the electrical bias and collecting it in the O_2 gas storage (154); and
implementing a six-stage reaction procedure wherein H_2 and O_2 generation stages are stage 1 and stage 4, and remaining stages are intermediate stages used for exchange of fluids between chambers through coordinated operation of the valve lines (136) and control system (118).
In an embodiment, a driving force of approximately 2-120 mV may be applied to facilitate the hydrogen production, and the method may achieve theoretical efficiencies reaching up to 95% based on Higher Heating Value (HHV) through selective and temporally separated electrochemical reactions.
In an exemplary embodiment, H2 is generated at the cathode electrode (112) under ambient conditions, while O2 evolution is arrested by oxidizing the redox-active anode electrode (106). The stored oxygen is later released through thermal regeneration of the oxidized anode. Although conventional systems such as the Electrochemical–Thermally Activated Chemical (E-TAC) process implement a similar two-step method using multiple cells constantly filled with heated electrolyte, these conventional systems present challenges due to the need for rapid heating and cooling cycles. The disclosed method overcomes these issues by localizing heat application, simplifying thermal management, and thereby improving cell stability, efficiency, and scalability.
Thus, the multi-chamber assembly (124) utilizes a compact and modular sandwich assembly (104) design integrated with controlled gas exchange, the intermediate holding unit (142), and regulated thermal management, resulting in enhanced energy efficiency, scalability, and hydrogen purity. This controlled thermal actuation improves efficiency and prolongs the operational life of the integrated electrolysis system. The sandwich assembly (104) limits unnecessary heating and facilitates effective heat dissipation. In an exemplary embodiment, the sandwich assembly (104) design may be in multiple forms, including, but not limited to, parallel plates or in the form of a spiral jelly roll to increase space utilization within a cell structure.
The present utilizing the electrolyzer cells (102) configuration in which hydrogen and oxygen evolution steps are separated both spatially and temporally. Localized heating of the anode is achieved using the dedicated heating member (116), while the electrolyte remains cold during hydrogen generation. The electrolytes are cyclically exchanged between the one or more electrolyzer cells (102) comprising the first cell and the second cell, eliminating the entire system heating and cooling, thereby reducing energy consumption and improving cycle efficiency.
In an exemplary embodiment of the present disclosure, the multi-chamber system comprises the integrated system of components interconnected through the one or more valve lines (136), the one or more sensors (144), and the control system (118). Herein, the first and second electrolyzer cells are fluidically connected to each other and to the intermediate holding unit (142) through the one or more valve lines (136) equipped with two-way solenoid valves (138). Certain valve lines (136) may further incorporate heat exchangers (160) to regulate the temperature of the circulating electrolyte (128). The two-way solenoid valves (138) are operably linked to the control system (118) via the one or more terminals (148), enabling real-time actuation based on inputs from the associated one or more sensors (144). For example, each of the valve lines (136) includes two-way solenoid valves (138) electrically connected to the control system (118) via terminals (148), allowing real-time actuation based on sensor feedback. The buffer chamber is also connected to the fluid reservoir and the non-reactive gas storage (158), facilitating controlled electrolyte exchange and purging operations.
In another exemplary embodiment, the multi-chamber system comprises the integrated system with the one or more electrolyzer cells (102) which consists of NaOH or KOH as the electrolyte (128), and the anode electrode (106) and cathode electrode (112). Further, the integrated system operates via transfer of hydroxide ion through the electrolyte (128) from the cathode electrode (112) to the anode electrode (106) with H2 produced on the cathode electrode (112). Further, oxygen generation occurs at the anode electrode (106) by increasing the temperature of the anode electrode (106) using the heating member (116). Both the cathode electrode (112) and anode electrode (106) are assembled in a unique sandwich assembly (104).
The one or more electrical connections (110) link the cell assembly (100) to the respective positive and negative terminals of the power supply (108), thereby enabling appropriate electrical biasing required for electrochemical reactions. In an exemplary embodiment, the three-way valve (140) mounted on an opening (146) may be operably connected to the cell assembly (100) and is configured to direct flow toward the hydrogen and oxygen gas storage units. This valve is further interfaced with an oxygen sensor to ensure selective and safe gas handling. Both the electrical connections (110) and the valve are controlled via the control system (118) through the designated one or more terminals (148), enabling synchronized fluid and gas flow, precise thermal regulation, and efficient operation of the electrolysis process. This integrated arrangement ensures synchronized fluid and gas flow, precise thermal management, and efficient electrolysis operation.
In an exemplary embodiment, a six-stage reaction procedure is implemented by the present disclosure. The reaction stages (i.e. H2 and O2 generation stages) are stage 1 and 4, while the remaining stages are intermediate, which are used for exchange of fluids in the two chambers. The integrated system operates in a following manner: Initially without the electrical bias and at ambient temperature, the system is said to be in a state of zero bias. A fluid solution is pumped into the first cell and the second cell. In the second cell, the heating member (116) at the anode electrode (106) heats the electrolyte (128). Further, the system enters stage 1 including first cell containing the cold electrolyte, the second cell containing the hot electrolyte, and the buffer chamber containing the non-reactive gas. Then, the electric bias is applied to the first cell which leads to reduction of the fluid solution, generation of hydroxide ions and evolution of H2 gas at the cathode electrode (112) according to a half reaction mentioned in equation [1] and equation [2]. The evolved H2 gas is collected by gas storage through a specific outlet and the 3-way valve systems. During the H2 generation step, hydroxide ions get transported to the anode and converts the Nickel hydroxide (Ni(OH)2) on anode to Nickel oxyhydroxide (NiOOH) according to the reaction mentioned in equation [2] to arrest the O2 production at the ambient temperature.
4H2O + 4e? ? 4OH? + 2H2 at E° = 0 VRHE ? [1]
and,
Ni(OH)2 + OH? ? NiOOH + H2O + e? at E° = 1.42 VRHE ? [2]
Now, the electrolyte (128) is drained to the buffer from the first cell and the first cell is purged with the non-reactive gas from the buffer chamber by turning on the certain valve lines (136). This made the integrated system entry in stage 2 having the first cell containing the non-reactive gas, the second cell containing the hot electrolyte, and the buffer chamber containing the cold electrolyte. Now, from the first cell, the non-reactive gas is pumped to the second cell, and the hot electrolyte is pumped in the first cell from the second cell by the certain valve lines (136). Further, in stage 3, the first cell containing the hot electrolyte, the second cell containing the non-reactive gas, and the buffer chamber containing the cold electrolyte. Further, the non-reactive gas form the second cell is purged to the buffer chamber, and the cold electrolyte from the buffer chamber is pumped to the second cell by the certain valve lines (136), making the integrated system entry to stage 4 having the first cell containing the hot electrolyte, the second cell containing the cold electrolyte, and the buffer chamber containing the non-reactive gas. This leads to anode regeneration by release of O2 without the electrical bias as mentioned in the following reaction
4NiOOH + 2H2O ? 4Ni(OH)2 + O2 ? [3]
Although the reaction described in equation [1] requires a minimal driving force of approximately 2-120 mV, the evolution of O2 at ambient temperature remains inherently slow. To overcome this, the present disclosure employs a unique sandwich assembly (104) of the anode electrode (106) and cathode electrode (112), and the anode electrode (106) is thermally activated through an integrated heating member (116). The evolved O2 gas may be collected via the 3-way valve system through a designated outlet. The molarity of the electrolyte solution is maintained consistently throughout the process by replenishing water from the fluid reservoir positioned below the buffer chamber.
Furthermore, the electrolyte (128) and gas contents are sequentially exchanged between the first cell and the buffer chamber via dedicated pump and valve lines (136), transitioning the system into stage 5 having the first cell containing the non-reactive gas, the second cell containing the cold electrolyte, and the buffer chamber containing the hot electrolyte, as carried forward from stage 4. Subsequently, the contents of the first and second cells are exchanged via specific valve lines (136), leading the system into stage 6 having the first cell containing the cold electrolyte, the second cell containing the non-reactive gas, and the buffer chamber containing the hot electrolyte. Finally, the hot aqueous solution from the buffer chamber is transferred to the second cell, thereby returning the integrated system to stage 1, with the first cell containing cold electrolyte, the second cell containing hot electrolyte, and the buffer chamber containing the non-reactive gas.This is one complete cycle. This mechanism and the multi-chamber assembly (124) with integrated system avoid mixing of the H2 and O2 gases and further storage and transportation issues.
The presently disclosed cell assembly (100) and the method for high-efficient production of H2 through electrolysis shows significant applications in the field of green hydrogen production, offering a sustainable and efficient solution to address global energy challenges. By enabling high-purity H2 generation through a decarbonized electrolysis process, the system supports a wide range of industrial and energy-sector applications. The system may be effectively utilized in decarbonizing hard-to-abate industries such as steel and cement, which are conventionally reliant on fossil fuels. Furthermore, the disclosed technology holds strong potential in the transportation sector, particularly for powering fuel cell electric vehicles (FCEVs), by providing a clean, high-efficiency hydrogen fuel alternative that contributes to substantial reduction in carbon emissions and promotes the global shift towards net-zero energy systems.
Figure 1 illustrates a detailed cross-sectional view of the sandwich electrode assembly (104) in an isometric perspective. The assembly comprises multiple parallel layers including a cathode sheet positioned at the front, followed by a spacer (114) that maintains a defined gap labeled as "space between electrodes." Behind the spacer is an anode sheet, which is followed by a heating element (116), and finally an insulating sheet (120) at the back of the assembly. The structure includes electrical connection points labeled as e1, e2, e3, and e4, with the cathode marked with "+" (e1) and anode marked with "-" (e3). The entire assembly is held together with fasteners visible at the corners of the plates, and the spacer (114) runs along the edges of the electrodes to maintain consistent separation between the cathode electrode (112) and anode electrode (106) surfaces. This technical illustration demonstrates the spatial relationship and layered construction of the key functional elements in the electrode assembly.
Figure 2 illustrates a comprehensive technical schematic diagram of the multi-chamber electrolysis system (100) showing the complete system architecture. The diagram depicts two main electrolyzer chambers labeled "A" and "B" that are identical in construction, each containing internal electrode components and multiple connection points labeled with "o1" through "o5." A central control unit is positioned at the top of the system, connected to various components through control lines represented by dotted lines. The system includes a buffer chamber (C) positioned below chambers A and B, which connects to water and inert gas inputs at the bottom along with a feed tank. Multiple valves, heat exchangers, and flow control elements are depicted throughout the system, connected by solid lines representing physical connections and dotted lines indicating control signals. The chambers are interconnected via a series of control valves and flow lines, creating a sophisticated fluid and gas handling system with precise control mechanisms for managing flow between the chambers.
Figure 3(a) illustrates a side view technical drawing of the cell stack assembly showing the layered construction in cross-section. The structure consists of multiple parallel horizontal plates or layers stacked together with small gaps between them, revealing the internal arrangement of the electrode assembly components. The overall profile appears thin and elongated horizontally, with the layers appearing to be of similar width but potentially different thicknesses. The assembly shows some slight protrusions or variations in thickness at certain points along its length, demonstrating the modular nature of the electrode stack construction.
Figure 3(b) illustrates a cell stack assembly view in an isometric perspective showing the compact electrode arrangement. The assembly consists of multiple parallel plates stacked together with small gaps between them, with end vertical covering plates (164) that appear to be mounting or support plates. The central section between the outer plates contains the electrode plates and spacing elements. The overall construction appears modular, with the components held together in a compact arrangement that allows visualization of both the front face and one side of the assembly structure.
Figure 3(c) illustrates an exploded view technical drawing of the cell stack assembly showing how the individual components fit together. The drawing depicts a covering plate (162) or panel on one side, connected via four long fasteners or bolts to a mounting bracket or housing structure. The housing structure has multiple protruding elements or posts, and dotted lines indicate the assembly path for the fasteners through both the flat panel and the housing components. This exploded view demonstrates the mounting and attachment system for the electrode assembly components and shows how they are designed to be assembled together.
Figure 3(d) illustrates an electrode assembly transverse view showing the cross-sectional arrangement of the sandwich structure components. The diagram displays the multiple labeled layers arranged in a sandwich configuration, with a cathode electrode (112) and anode electrode (106) separated by a spacer (114) indicated by a shaded area. Below the electrodes is a heating element (116), and at the bottom of the assembly is an insulating sheet (120). The diagram uses arrows and text labels to clearly identify each component, illustrating the basic construction and spatial relationship between the key functional elements of the electrode assembly and showing how they are stacked together while maintaining separation through the spacer layer.
Figure 4 illustrates the detailed multi-chamber cell assembly (100) connections showing the complete system integration and control architecture. The diagram depicts the two-cell electrolysis system with associated control components, including two main chambers labeled "A" and "B" connected via a series of flow paths and valves. A control unit is shown at the top with various control lines indicated, and between the chambers is a buffer chamber (C) that connects to both water and inert gas inputs at the bottom. Each cell appears to have multiple inlet/outlet ports, electrical connections (110), and internal electrode assemblies. The system includes heat exchangers (160), flow control valves, and sensor connections (144) arranged in a closed-loop configuration, with standard engineering symbols used for valves, sensors (144), and flow paths. Dotted lines indicate control signals while solid lines show physical connections, demonstrating the sophisticated fluid and gas handling system designed for controlled electrolysis operations with precise temperature and flow management capabilities.
In an embodiment, the advantages of the present invention are discussed herein;
The present invention is to provide a cell assembly and method for hydrogen production through electrolysis that offers several advantages over conventional systems:
The present invention is to provide spatial and temporal separation of hydrogen and oxygen evolution, which eliminates the need for complex gas separation infrastructure and reduces safety risks associated with gas mixing during the electrolysis process.
The present invention is to provide localized heating of the anode electrode through the integrated heating member, which minimizes energy consumption by avoiding unnecessary heating of the entire electrolyte volume and surrounding cell components.
The present invention is to provide improved thermal management through the compact sandwich assembly design, which facilitates effective heat dissipation and reduces thermal stress on system components.
The present invention is to provide enhanced operational efficiency by eliminating the need for full system cooling between hydrogen and oxygen generation cycles, thereby reducing cycle times and improving overall process performance.
The present invention is to provide a modular and scalable system architecture that may be configured in multiple forms including parallel plates or spiral jelly roll configurations to optimize space utilization within cell structures.
The present invention is to provide controlled fluid exchange through the multi-chamber assembly with integrated valve lines and sensors, which enables precise management of electrolyte flow, temperature regulation, and gas handling operations.
The present invention is to provide high-purity hydrogen generation with theoretical efficiencies reaching up to 95% based on Higher Heating Value through selective and temporally separated electrochemical reactions.
The present invention is to provide reduced material degradation and extended operational life by minimizing rapid heating and cooling cycles that are typically required in conventional electrolysis systems.
The present invention is to provide simplified system operation through automated control algorithms that manage valve operations, heating, and power supply based on real-time sensor feedback.
The present invention is to provide cost-effective hydrogen production by reducing the complexity of gas separation equipment and minimizing energy losses associated with simultaneous gas evolution processes.
,CLAIMS:We Claim:
1. A cell assembly (100) for hydrogen (H2) production through electrolysis, the cell assembly (100) comprising:
(a) at least one electrolyzer cell (102), each electrolyzer cell (102) being configured with a sandwich assembly (104), the sandwich assembly (104) comprising:
(i) an anode electrode (106);
(ii) a cathode electrode (112);
(iii) a spacer (114) positioned between the anode electrode (106) and the cathode electrode (112) to maintain a constant gap there between;
(iv) a heating member (116) disposed behind the anode electrode (106) for providing localized heating, wherein the heating member (116) is in thermal contact with the anode electrode (106);
(v) an insulating sheet (120) positioned adjacent to the heating member (116) opposite to the anode electrode (106), wherein the insulating sheet (120) thermally isolates the heating member (116) from surrounding components; and
(vi) an electrically conducting metal tab (122) configured to provide electrical bias by connecting the anode electrode (106) and the cathode electrode (112) at respective edges thereof, wherein the electrically conducting metal tab (122) is in electrical communication with the power supply (108);
(b) a multi-chamber assembly (124) operatively connected to the at least one electrolyzer cell (102), the multi-chamber assembly (124) comprising:
(i) an electrolyte (128);
(ii) a cell-connection assembly (130) having at least one inlet (132) and at least one outlet (134);
(iii) one or more valve lines (136) including two-way solenoid valves (138) and three-way valves (140), wherein the valve lines (136) fluidically connect the at least one electrolyzer cell (102) to the intermediate holding unit (142);
(iv) one or more sensors (144) configured to monitor operating conditions within the cell assembly (100);
(v) a control system (118) operatively connected to the one or more sensors (144) and configured to manage operation of the valve lines (136), heating member (116), and power supply (108);
(vi) one or more electrical connections (110) configured to link the anode electrode (106) and the cathode electrode (112) to the power supply (108);
(vii) a power supply (108) electrically connected to the anode electrode (106) and the cathode electrode (112) through the one or more electrical connections (110);
(viii) one or more openings (146) configured to allow gas release and electrolyte exchange;
(ix) one or more terminals (148) configured to interface the control system (118) with the valve lines (136) and the power supply (108);
(x) associated fluid storage units (150) including at least one of H2 gas storage (152), O2 gas storage (154), water reservoir (156), and non-reactive gas storage (158); and
(xi) an intermediate holding unit (142).
2. The cell assembly (100) as claimed in claim 1, wherein the sandwich assembly (104) is configured to enable spatial and temporal separation of hydrogen (H2) and oxygen (O2) evolution by arresting O2 generation during H2 production through oxidation of the anode electrode (106) during hydrogen generation at ambient temperature, followed by releasing O2 upon heating the oxidized anode electrode (106).
3. The cell assembly (100) as claimed in claim 1, wherein the one or more valve lines (136) are configured to fluidically connect the electrolyzer cells (102) to each other and to the intermediate holding unit (142).
4. The cell assembly (100) as claimed in claim 1, wherein certain valve lines (136) incorporate heat exchangers (160) configured to regulate temperature of circulating electrolyte (128) based on signals received from the one or more sensors (144).
5. The cell assembly (100) as claimed in claim 1, wherein the one or more electrical connections (110) are configured to link the cell assembly (100) to respective positive and negative terminals of the power supply (108).
6. The cell assembly (100) as claimed in claim 1, wherein the control system (118) is interfaced via the one or more terminals (148) to manage operation of the valve lines (136), heating, and power supply (108).
7. The cell assembly (100) as claimed in claim 1, wherein the intermediate holding unit (142) functions as a buffer chamber acting as a temporary storage and regulating unit for fluids during the electrolysis process.
8. The cell assembly (100) as claimed in claim 1, wherein the sandwich assembly (104) design is configured in multiple forms including parallel plates or in a form of a spiral jelly roll to increase space utilization within a cell structure.
9. The cell assembly (100) as claimed claim 1, wherein the electrolyte (128) is selected from alkali solutions including potassium hydroxide (KOH) or sodium hydroxide (NaOH).
10. The cell assembly (100) as claimed claim 1, wherein the one or more electrolyzer cells (102) are purged in a cyclic manner using the non-reactive gas following evolution of H2 and O2, and the non-reactive gas operates in a closed-loop configuration as a separating medium between cold electrolyte (128) and hot electrolyte (128).
11. The cell assembly (100) as claimed in claim 1, wherein the anode electrode (106) comprises nickel hydroxide (Ni(OH)2) configured to convert into nickel oxyhydroxide (NiOOH) during the electrolysis process.
12. The cell assembly (100) as claimed in claim 1, wherein the heating member (116) is configured to provide localized heating to the anode electrode (106) without heating the entire electrolyte (128) volume.
13. A method for hydrogen (H2) production through electrolysis, comprising:
a) pumping an electrolyte (128) into one or more electrolyzer cells (102) in absence of an electrical bias;
b) locally heating the electrolyte (128) using a heating member (116) positioned at an anode electrode (106) of a first cell from the one or more electrolyzer cells (102);
c) applying the electrical bias to the first cell to initiate electrochemical reduction of the electrolyte (128), generation of hydroxide ions, oxidation of the anode electrode (106), and evolution of H2 gas at a cathode electrode (112);
d) collecting the evolved H2 gas and directing it to an associated gas storage unit;
e) converting nickel hydroxide (Ni(OH)2) into nickel oxyhydroxide (NiOOH) at the anode electrode (106) to arrest O2 evolution at ambient temperature;
f) transferring the electrolyte (128) from the first cell to an intermediate holding unit (142);
g) purging the first cell with a non-reactive gas from the intermediate holding unit (142);
h) pumping the non-reactive gas from the first cell into a second cell;
i) pumping hot electrolyte (128) from the second cell into the first cell to cause thermal regeneration of the oxidized anode electrode (106);
j) releasing O2 gas without application of the electrical bias; and
k) implementing a six-stage reaction procedure wherein H2 and O2 generation stages are stage 1 and stage 4, and remaining stages are intermediate stages used for exchange of fluids between chambers.
14. The method as claimed in claim 13, wherein a driving force of approximately 2-120 mV is applied to facilitate the hydrogen production, and the method achieves theoretical efficiencies reaching up to 95% based on Higher Heating Value (HHV) through selective and temporally separated electrochemical reactions.