US20220186386A1

US20220186386A1 - Electrolyzer with improved electrode structure

Info

Publication number: US20220186386A1
Application number: US17/497,471
Authority: US
Inventors: Daniel James Warren
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-10-13
Filing date: 2021-10-08
Publication date: 2022-06-16

Abstract

An electrolyzer is disclosed. The electrolyzer includes a container, electrode ports, and a plurality of electrodes that extend from outside of the container through the electrode ports into the container. The plurality of electrodes wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 63/091,093, filed Oct. 13, 2020, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

Embodiments of the disclosure pertain to electrolyzers and, in particular, to an electrolyzer with an improved electrode structure.

BACKGROUND

Conventional electrolyzers often have designs which either exclude significant portions their electrodes' surface area from solution or include electrode parts which leak more current into the solution than does surrounding electrode parts, both of which are problematic. The exclusion of significant portions of electrode surface area from solution in what is sometimes referred to as ‘dry cell’ electrolyzer design is problematic because electrode material is wasted in the construction of the unit. The inclusion of electrode parts which leak excess current into the solution as compared to surrounding electrode surfaces in what is sometimes referred to as ‘wet cell’ electrolyzer design is problematic because the current drain from the current leakage decreases the overall efficiency of that electrolyzer. Furthermore, most electrolyzers have multiple holes in their lids for ports for wire connections, gas outlet pipes, gauges, and/or valves. Some electrolyzers include a large number of gaskets throughout the unit which can lead to sealing issues. The large number of holes and seals in electrolyzers increases the likelihood of leakage from the unit and may increase the time it takes to construct/manufacture such items.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows typical operating environments of an electrolyzer with improved electrode structure according to an embodiment.

FIG. 1B shows an electrolyzer with an improved electrode structure according to an embodiment.

FIG. 1C shows the manner in which a portion of the winding structure of wire electrodes spiral downward according to an embodiment.

FIG. 1D illustrates an exemplary winding structure of wire electrodes which includes first radially related spiral rings that spiral downward and second radially related spiral rings that spiral upward according to an embodiment.

FIG. 1E shows a top view of an exemplary structure of wire electrodes that includes a plurality of descending and ascending groups of radially related spiral rings that are concentrically ordered according to an embodiment.

FIG. 1F shows a perspective view of the plurality of rings shown in FIG. 1E and an expanded view of the plurality of rings according to an embodiment.

FIG. 1G shows a frame assembly that uses the electrode structure described with respect to FIG. 1F according to an embodiment.

FIG. 1H shows a perspective view of a ported outlet pipe according to an embodiment.

FIG. 1I shows a top view of parts of an electrolyzer according to an embodiment.

FIG. 1J shows operations performed by an electrolyzer with improved electrode structure according to an embodiment.

FIG. 1K shows a first component of a bracket assembly according to another embodiment.

FIG. 1L shows a second component of a bracket assembly according to another embodiment.

FIG. 1M shows a third component of a bracket assembly according to another embodiment.

FIG. 2 shows a flowchart of a method for forming an electrolyzer with improved electrode structure according to an embodiment

FIG. 3 shows a flowchart of a method for forming a bracket according to an embodiment.

DESCRIPTION OF THE EMBODIMENTS

An electrolyzer with improved electrode structure is described. It should be appreciated that although embodiments are described herein with reference to example electrolyzers with improved electrode structure, the disclosure is generally applicable to electrolyzers with improved electrode structure as well as other type electrodes with improved electrode structure. In the following description, numerous specific details are set forth, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without these specific details. In other instances, well-known features, are not described in detail in order to not unnecessarily obscure embodiments of the present disclosure. Furthermore, it is to be appreciated that the various embodiments shown in the Figures are illustrative representations and are not necessarily drawn to scale.
Certain terminology may also be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, and “side” describe the orientation and/or location of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.
Electricity is passed through wire electrodes immersed in an electrolytic solution to interact with the electrolytic solution in a manner that drives an electrochemical, reaction, whose products may include, but are not limited to, hydrogen, oxygen, hydroxyls, and/or oxyhydrogen. The wire electrodes enter and exit the electrolyzer container through ports in a ported outlet pipe. The ported outlet pipe passes through a hole in the electrolyzer lid, and is held in place and sealed with a grommet. The generated gas exits the electrolyzer through a gas outlet port at the end of the ported outlet pipe. A bracket (or any suitable electrode supporting framework) is secured to the ported outlet pipe and may contain spaces (e.g., holes, spaces of various geometric shape and/or structure) through which the wire electrodes pass. The wire electrodes in order to arrange the wire electrodes in a manner which optimizes any number of aspects, including, but not limited to: the size of the container, and the configuration, length, spacing, and gauge of the wire.
The exclusion of significant fractions of electrode surface area from solution in what is sometimes referred to as ‘dry cell’ electrolyzer design is problematic because electrode material is wasted in the construction of that unit. The inclusion of electrode parts which leak excess current into the solution as compared to surrounding electrode surfaces in what is sometimes referred to as ‘wet cell’ electrolyzer design is problematic because the current drain decreases the overall efficiency of that electrolyzer. Furthermore, most electrolyzers have multiple holes in their lid that may include ports for wire connections, gas outlet pipes, gauges, and/or valves. Some electrolyzers include a large number of gaskets throughout the unit which can lead to sealing issues. The large number of holes and seals in electrolyzers increases the likelihood of leakage from the unit and may increase the time it takes to construct/manufacture electrolyzers.
A process and device that overcomes the shortcomings of such approaches is described herein. As part of a disclosed approach, an electrolyzer is provided that includes a container; electrode ports coupled to the container; and a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode entrance ports, and in a second direction toward the electrode entrance ports. In an embodiment, the electrolyzer can include a bracket inside the container that extends away from the electrode entrance ports. In an embodiment, the plurality of electrodes can be held in place by the bracket.

Typical Operating Environment of Electrolyzer with Improved Electrode Structure

FIG. 1A shows typical operating environments 10 of an electrolyzer according to an embodiment. FIG. 1A shows windmills 12, solar panels 14, grid 16, electrolyzers 100 a-100 d, 18 a (gas), user 18 b (industry), user 18 c (refinery), and user 18 d (refueling station).
Referring to FIG. 1A, windmills 12 and solar panels 14 generate electricity that is delivered to grid 16. Grid 16 distributes the electricity to electrolyzers 18 a-18 d. Electrolyzers 100 a-100 d receive the electricity from grid 16 and produce hydrogen. Electrolyzers 100 a-100 d are each associated with an users 18 a-18 d of the hydrogen that they produce. Users can include but are not limited to commercial, industrial and residential end users.
In an embodiment, electrolyzers 100 a-100 d produce hydrogen without excluding significant fractions of electrode surface area from solution in what is sometimes referred to as ‘dry cell’ electrolyzer design. In addition, electrolyzers 100 a-100 d avoid the inclusion of electrode parts which leak excess current into the solution as compared to surrounding electrode surfaces in what is sometimes referred to as ‘wet cell electrolyzer design in order to avoid current drain that decreases the overall efficiency of that electrolyzer. The structure of electrolyzers 100 a-100 d are described herein in detail with reference to FIG. 1B.
In an embodiment, the hydrogen that is generated can be converted, or stored for later conversion into electricity or for other purposes. For example, the hydrogen can be converted into electricity by means that include but are not limited to fuel cells, turbines, or engines.

Electrolyzer with Improved Electrode Structure

FIG. 1B shows an electrolyzer 100 with improved electrode structure according to an embodiment. In the embodiment of FIG. 1B, electrolyzer 100 includes bracket 102, wire electrodes 104, below lid gas ports 106, below lid electrode ports 108, below lid nut 110, lid 112, grommet 114, above lid nut 116, above lid electrode ports 118, electrode leads 120, ported outlet pipe 122, pressure release valve 124, gas outlet port 126, and container 128.
Referring to FIG. 1B, in an embodiment, bracket 102 is coupled to a portion of ported outlet pipe 122 that extends into container 128. In an embodiment, bracket 102 includes four panels 102 a-102 n that viewed from above (after assembly) have a geometric shape of a “plus sign” or “cross.” In other embodiments, bracket 102 includes other numbers of panels and can appear differently when viewed from above. In an embodiment, panels 102 a-102 n make contact at the center of container 128 at similar edges, and extend away from the center of the container toward the walls of container 128. In an embodiment, panels 102 a-102 n contain spaces that are configured to hold wire electrodes 104 in place. In an embodiment, spaces 103 form rows that extend from near the top to near the bottom of each of the panels 102 a-102 n of bracket 102. In an embodiment, each row includes several spaces 103. In other embodiments, each row can include less than several spaces 103. In an embodiment, bracket 102 can extend from a point just underneath lid 112 of container 128 to a point near or at the opposite (inside) end of container 128. In other embodiments, bracket 102 can extend to lesser distances, away from lid 112, inside container 128. In other embodiments, bracket can extend upward from the bottom of container 128.
In an embodiment, spaces 103 are used to lace wire electrodes 104 in descending and ascending concentric spiral ring patterns through bracket 102. In an embodiment, wire electrodes 104 are configured such that the spirals wind in a first direction away from lid 112 and in a second direction toward lid 112. In other embodiments, wire electrodes 104 can be laced through the bracket 102 in other manners.
FIGS. 1C-1E show perspective views of wire electrodes or portions thereof according to an embodiment. In an embodiment, wire electrodes can include three vertically aligned wires (positive, negative, and neutral) that form concentric rings. In other embodiments, wire electrodes can include other numbers of wires. In an embodiment, the three vertically aligned wires can be strictly aligned. In other embodiments, the three vertically aligned wires can be more loosely aligned. FIG. 1C shows the manner in which a portion 104 a of wire electrodes 104 (FIG. 1B) spiral in container 128 (FIG. 1B). As shown in FIG. 1C wire electrode portion 104 a comprise three concentrically spiraling wires wherein the top and bottom wires are placed at equal distances from the center wire. In other embodiments, the top and bottom wire can be placed at different distances from the center wire. FIG. 1D illustrates an exemplary winding structure 104 b of wire electrodes 104 (FIG. 1B) which includes first radially related spiral rings that spiral downward (labelled “A”) and second radially related spiral rings that spiral upward (labelled “B”), outside of first radially related spiral rings (based on a larger radius). FIG. 1E shows a top view of an exemplary structure 104 c of wire electrodes 104 (FIG. 1B) that includes a plurality of descending and ascending groups of radially related spiral rings that are concentrically ordered. As shown in FIG. 1E, two pairs of descending and ascending groups of radially related spiral rings provide a four-ring wire electrode structure. However, other numbers of pairs of descending and ascending groups of radially related spiral rings can be used. FIG. 1F shows both a perspective view of the four-ring wire electrode structure shown in FIG. 1E (at bottom) and an expanded view of the four-ring wire electrode structure with individual groups of radially related spiral rings visible (above that). FIG. 1G shows a bracket assembly with a plurality of radially related spiral rings concentrically laced using the electrode structure described with respect to FIGS. 1E and 1F. In an embodiment, because it is a three-wire electrode arrangement, it includes six connection points, or ends of wires, three of which extend from the top of the first group of radially related spiral rings, and three of which extend from the top of the last group of radially related spiral rings. In an embodiment, these six wires exit container 128 (FIG. 1B) through electrode ports 118 (FIG. 1B) on ported outlet pipe 122 (see especially FIG. 1I below). In other embodiments, other wire electrode configurations can be used. For example, in other embodiments, wire electrodes 104 can include two wires (positive and negative) that wind through bracket 102, and have four connection points, or ends of wires, that exit through ported outlet pipe 122.
Referring again to FIG. 1B, wire electrodes 104 enter and exit electrolyzer 100 through ported outlet pipe 122. In particular, electrodes 104 enter and exit electrolyzer 100 through isolated ports on ported outlet pipe 122. In an embodiment, after entering electrolyzer 100, electrodes 104 are laced through spaces 103 in bracket 102.
In an embodiment, when a lacing of a series of spirals/rings of electrode 104 from top to bottom or bottom to top (or vice versa) has been completed, subsequent concentric spirals/rings can be commenced using a slight extension of their radius from the center of the bracket, at the bottom or the top of the assembly. At this point wire electrodes 104 can change their vertical direction of travel from ascending to descending, or vice versa. In an embodiment, wire electrodes 104 can be arranged within the electrolyzer 100 in any manner which optimizes any number of aspects, including, but not limited to: the size of the container; the volume of solution exposed to electrolytic forces; the quantity of electrolyte material needed to produce a unit of gas; and the configuration, length, spacing, and gauge of the wire suspended in solution.
In an embodiment, bracket 102 can be assembled as wire electrodes 104 are being wound to form concentric spirals. In this embodiment, an initial portion of bracket 102 is configured to accommodate the first concentric ring. Subsequently, after the first ascending/descending series of rings is completed, the radius of the ring formed by wire electrodes 104 from the center of bracket 102 can be extended to establish the spacing for the second ascending/descending series of concentric rings, and the next portion of bracket 102. In an embodiment, the next portion of bracket 102 can be formed outside of the previously formed portion of bracket 102. In an embodiment, wire electrodes 104 can be configured to change vertical directions when each group of ascending/descending rings is completed, changing from descending to ascending, or vice versa. In an embodiment, when a portion of bracket 102 has been completed as described above, wire electrodes 104 can then be wound about the newly completed portion of bracket 102. In an embodiment, this process can be repeated until the desired number of concentric rings, or length of wire, is reached. In an embodiment, the beginning and end portions of wire electrodes 104 left after the final concentric spiral ring is completed can be threaded through respective wire electrode ports 118 on the ported outlet pipe 122. In other embodiments, other manners of assembling and lacing bracket 102 can be used.
In an embodiment, bracket 102 can be connected to the ported outlet pipe 122 using a threaded bolt type protuberance on the top of the bracket 102 and a corresponding threaded hole in the bottom of the ported outlet pipe 122, or any other type connection device, such as, but not limited to: screws, rivets, snap fits, holding pins, tabs, plastic welding, adhesives, tapes, epoxies, and/or specialty options. In an embodiment, lid 112 covers the opening of container 128. In an embodiment, the opening is located at the top or end of container 128. In an embodiment, lid 112 can be attached to container 128 via a latching mechanism, or any other suitable fastening mechanism. In an embodiment, lid 112 and container 128 can have a seal located therebetween.
In an embodiment, below lid gas ports 106 include respective ports through which gas enters and exits container 128. In an embodiment, below lid electrode ports 108 are a part of ported outlet pipe 122. In other embodiments, below lid electrode ports 108 may not be a part of ported outlet pipe 122. In an embodiment, below lid electrode ports 108 include respective ports through which wire electrodes 104 enter and exit container 128. In an embodiment, below lid electrode ports 108 includes ports for positive and negative electrodes. In other embodiments, below lid electrode ports 108 includes ports for positive, negative and neutral electrodes.
In an embodiment, below lid nut 110 and above lid nut 116 are fasteners that are used to fasten parts of electrolyzer 100 together. For example, in an embodiment, below lid nut 110 and above lid nut 116 are used to fasten ported outlet pipe 122 and bracket 102 to container 128 via lid 112. In an embodiment, the ported outlet pipe 122 (as was described above) and other parts can include threading to facilitate the fastening of the parts.
In an embodiment, above lid electrode ports 118 are a part of the ported outlet pipe 122. In other embodiments, above lid electrode ports 118 can be located in other places. In an embodiment, leads 120 (which can be positive, negative, neutral or ground) are end points of wire electrodes 104 and are directed by above lid electrode ports 118 into container 128. In an embodiment, positive leads 120 receive electrical current electricity sources which wire electrodes 104 carry into container 128.
In an embodiment, ported outlet pipe 122 directs gas generated in container 128 to an opening through which the gas can be output. In an embodiment, ported outlet pipe 122 includes pressure release valve 124 and gas outlet port 126. In an embodiment, ported outlet pipe 122 can include threads, nuts and/or other type fastening features. In an embodiment, pressure release valve 124 controls or limits the pressure in container 128 by allowing the pressurized gas to flow through an auxiliary passage out of container 128. In an embodiment, gas outlet port 126 is an opening through which gas generated inside container 128 is delivered to external sources.
As shown in FIG. 1B, a portion of the ported outlet pipe 122 extends into container 128. In an embodiment, ported outlet pipe 122 enters container 128 through lid 112. In an embodiment, a gasket can be placed between the container and lid 112. In an embodiment, ported outlet pipe 122 is sealed at the location where it passes through the hole in lid 112 with grommet 114. In other embodiments, the ported outlet pipe 122 can be sealed in other manners. Moreover, in an embodiment, these fixtures can be fastened above and below grommet 114 to provide additional mechanical pressure around grommet 114 for enhanced seal stabilization.
FIG. 1H shows a perspective view of ported outlet pipe 122 according to an embodiment. FIG. 1H shows in addition to below lid gas ports 106, below lid electrode ports 108, above lid electrode ports 118, pressure release valve 124, and gas outlet port 126 shown in FIG. 1B, above lid threading 130 for nut, below lid threading 132 for nut, and bracket connection point 134. Referring to FIG. 1H above lid threading 130 and below lid threading 132 are threading that enables ported outlet pipe 122 to be affixed to container 128 (FIG. 1B) via lid 112 (FIG. 1B). The threading can be used to fasten ported outlet pipe 122 above and below grommet 114 with nuts to provide mechanical pressure around grommet 114 for seal stabilization. Bracket connection point 134 is where bracket 102 is connected to ported outlet pipe 122. In an embodiment, ported outlet pipe 122 can include threading to connect bracket 102 (FIG. 1B) at bracket connection point 134. In other embodiments, other fastening mechanisms and/or techniques can be used to connect bracket 102 (FIG. 1B) at bracket connection point 134. FIG. 1I shows a top view of parts of the electrolyzer 100 that include lid 112, ported outlet pipe 122, pressure release valve 124, and gas outlet port 126, shown in FIG. 1B, in addition to positive electrode lead 120 a, negative electrode lead 120 b, and neutral electrode lead 120 c.
Referring to FIG. 1I, the three-wire electrode structure that is shown therein is characterized by three wires entering the container and three wires exiting the container such that a total of six leads are visible above the lid. Using a three-wire electrode structure enables a wire electrode structure such as is shown in FIG. 1D where a series of spirals/rings of electrode 104 are laced from top to bottom or bottom to top (or vice versa) and includes at least one change in their vertical direction of travel from ascending to descending, or vice versa.
Referring to FIG. 1B, in an embodiment, container 128 can be formed from glass and/or polypropylene. In other embodiments, container 128 can be formed from other materials. In an embodiment, lid 112 can be formed from glass and/or polypropylene. In other embodiments, lid 112 can be formed form other materials. In an embodiment, grommet 114 or other type of gasket can be formed from silicon. In other embodiments, grommet 114 or other type gasket can be formed from other materials. In an embodiment, ported outlet pipe 122 can be formed from polypropylene. In other embodiments, ported outlet pipe 122 can be formed from other materials. In an embodiment, lid 112 and container 128 can have a seal between them that is formed from silicon. In other embodiments, lid 112 and container 128 can have a seal between them that is formed from other materials. In an embodiment, bracket 102, ported outlet pipe 122, nuts 110 and 116, container 128, and other fasteners can be manufactured using 3D printers, or injection molding. In other embodiments, bracket 102, ported outlet pipe 122, nuts 110 and 116, container 128, and other fasteners can be manufactured using other manufacturing methods.

Operation

FIG. 1J shows operations performed by electrolyzer 100 with improved electrode structure. The operations shown are merely exemplary and some of the operations shown may not be used in some embodiments. Referring to FIG. 1J, at A, electricity is transmitted to electrolyzer 100. In an embodiment, the electricity can be transmitted by different types of power sources. In an embodiment, direct current or alternating current electricity can be used, converted, inverted, delivered in waveforms, pulses, and/or at a range of current levels. In an embodiment, the electricity can be delivered to different types of electron affinity, that can include, but are not limited to: positive, negative, ground, and/or neutral wire electrodes.
At B, electricity flows through wire electrodes 104 that are immersed in an electrolytic solution. At C, the electricity interacts with the electrolytic solution in a manner that drives an electrochemical, reaction. At D, the electrochemical reaction causes the generation of products that may include, but are not limited to, hydrogen, oxygen, hydroxyls, and/or oxyhydrogen. In an embodiment, the concentric spiral electrode structure is able to produce hydrogen without excluding significant fractions of electrode surface area from solution such as is done in what is sometimes referred to as ‘dry cell’ electrolyzer designs. In addition, the winding configuration avoids the inclusion of electrode surfaces which leak excess current into the solution in a greater degree than surrounding electrode surfaces in what is sometimes referred to as ‘wet cell electrolyzer design and thus avoids the type of current drain that can decrease the overall efficiency of the electrolyzer. At E, the generated gas exits the electrolyzer 100 through a gas outlet port 126 at the end of ported outlet pipe 122.
As indicated above, in some embodiments bracket assembly configurations other than that shown in FIG. 1B can be used. For example, FIGS. 1K, 1L and 1M show components of a bracket assembly of an embodiment that has a different design than the bracket assembly that is shown in FIG. 1B. FIG. 1K shows a first component 140 of the bracket assembly according to the embodiment. Referring to FIG. 1K, the first component 140 is comprised of a circular or ring-shaped structure 142 that includes a plurality of upwardly extending notches 144 that surround an open center space 146. In an embodiment, the first component 140 can accommodate and engage a second component 150 of the bracket assembly which is shown in FIG. 1L. Referring to FIG. 1L, the second component 150 of the bracket assembly can include columnar parts 152 fit into the upwardly extending notches 144 of the first component 140 so as to hold the second component 150 in place and to help stabilize the bracket assembly. In an embodiment, the notches 144 are configured to form a snap fit with the bottom ends of columnar parts 152. In addition, the second component 150 can be comprised of a circular or ring-shaped top structure 156 from which the structures 154 extend into an open space located at the center of the ring-shaped top structure 156. In an embodiment, the structures 154 can have extending downward therefrom or have coupled thereto the columnar parts 152 of the second component 150. In an embodiment, the columnar parts 152 can extend downward, away from the circular or ring-shaped top structure 156, and can include spaces 158 formed therein for holding electrodes in place. In an embodiment, protrusions 159 are formed on the face and the sides of the parts 152, and are configured to interlock with divots in a corresponding, interlocking and concentric components, that have a radius that is larger than the radius of component 150. In an embodiment, in addition to bracket components 140, 150 and 160 bracket components with increasing radii can be added such that a nested arrangement of bracket components is formed. Moreover, as the radius of the bracket components increase, the number of column structures similar to columnar parts 152 per bracket portion may increase as the bracket portions increase in their radius. In an embodiment, the protrusions 159 can be formed in any shape and/or geometry that is suitable for attachment to a corresponding and interlocking concentric section of bracket. Referring again to FIG. 1L, in an embodiment, as a part of second component 150 spaces 155 are provided that are configured to attach subsequent bracket components, and divots 157 are provided to engage protrusions that are located on component 160 (e.g., protrusions 168) described below.
FIG. 1M shows a third component 160 of the bracket assembly associated with the first component 140 and the second component 150 according to an embodiment. In an embodiment, the third component 160 of the bracket assembly can include a multi-sided lower portion 162 that is configured to extend through the space that is located in the center of the second component 150 and can include a top portion 164 that includes parts that are nested inside the ring-shaped top structure 156 of second component 150. In an embodiment, an exposed portion 164 a, of the top portion 164, is configured as a male annular structure that enables attachment in a snap fit manner with female structure 134 shown in FIG. 1H. Referring to FIG. 1M, the multi-sided lower portion 162 of the third component 160 can include spaces 166 for holding one or more electrodes that wind, for example, from a top of the multi-sided lower portion 162, to the bottom of the multi-sided lower portion 162. In an embodiment, after winding downward and being held in place by spaces 166 of the third component 160, the one or more electrodes can wind upward, and be held in place by spaces 158 in the second component 150 as the one or more electrodes move from the bottom to top of the second component 150. In an embodiment, after winding upward and being held in place by spaces 158 of the second component 150, this pattern of winding can be continued and expanded by adding bracket components, similar to second component 150, that have concentrically larger radii which enable them to be nested. In an embodiment, protrusions 168 are configured to extend from a face of some of the structures, that are formed at the sides of the spaces 166. In an embodiment, the protrusions 168 have corresponding indents 157 that are formed along the inside wall of 152 into which the protrusions 168 can be placed for interlocking as part of a snap fit fastening mechanism. In an embodiment, the protrusions 168 can be formed in any shape and/or geometry that is suitable for coupling a corresponding and interlocking concentric section of the bracket (e.g., component 150), which has a larger radius than the third component 160. In other embodiments, other suitable fastening mechanisms can be used. It should be appreciated that the brackets described herein are exemplary, and other brackets or electrode support frameworks can be used. In an embodiment, in addition to enabling the scalability of the radius of the bracket, the bracket can be formed to any suitable length, and thus a scalability of the height of the bracket is enabled such as through vertical extensions of the bracket components such as second and third components 150 and 160.

Method for Forming an Electrolyzer with Improved Electrode Structure

FIG. 2 shows a flowchart 200 of a method for forming an electrolyzer according to an embodiment. The method includes at 201, providing a container, at 203, providing electrode ports coupled to the container, and at 205, providing a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports. In an embodiment, the method further includes providing a bracket inside the container to extend in a first direction away from the electrode ports.
FIG. 3 shows a flowchart 300 of a method for forming a bracket according to an embodiment. In an embodiment, as part of the method a bracket is assembled as wire electrodes are wound to form concentric spirals. Referring to FIG. 3, the method includes at 301, forming a first portion of a bracket to accommodate a first series of ascending/descending rings of conductive material. At 303, forming the first series of ascending/descending rings of conductive material by threading one or more strands of the conductive material through spaces in the first portion of the bracket. At 305, forming a subsequent portion of the bracket outside of the first portion of the bracket to accommodate a subsequent series of ascending/descending rings of conductive material. At 307, forming the subsequent series of ascending/descending rings of conductive material by threading one or more strands of conductive material through spaces in the subsequent portion of the bracket in a direction opposite that of a series of ascending/descending rings of conductive material that immediately precedes the subsequent series of ascending/descending rings of conductive material. At 309, repeating 305 and 307 until a predetermined number of ascending/descending rings of conductive material is reached. In an embodiment, the beginning and end portions of the wire electrodes that remain after the final concentric spiral ring is completed can be threaded through respective wire electrode ports on the ported outlet. In an embodiment, the ascending/descending rings of conductive material include wire electrodes. In an embodiment, the beginning and end portions of the wire electrodes are threaded through respective wire electrode ports on a ported outlet.
Example embodiment 1: An electrolyzer, comprising: a container; electrode ports coupled to the container; and a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.
Example embodiment 2: The electrolyzer of example embodiment 1, further including: a bracket inside the container extending in a first direction away from the electrode entrance ports.
Example embodiment 3: The electrolyzer of example embodiment 2, wherein the plurality of electrodes are held in place by the bracket.
Example embodiment 4: The electrolyzer of example embodiment 1, 2, or 3, further including a ported outlet pipe coupled to the container.
Example embodiment 5: The electrolyzer of example embodiment 4, wherein the ported outlet pipe includes the electrode ports.
Example embodiment 6: The electrolyzer of example embodiment 1, 2, 3, 4, or 5 wherein the radius of the wind in the first direction is less than the radius of the wind in the second direction.
Example embodiment 7: The electrolyzer of example embodiment 4, wherein the ported outlet pipe includes a bracket securing component.
Example embodiment 8: The electrolyzer of example embodiment 4, wherein the ported outlet pipe includes gas ports.
Example embodiment 9: The electrolyzer of example embodiment 4, wherein the ported outlet pipe includes a pressure release valve.
Example embodiment 10: An electrolyzer electrode assembly, comprising: at least a first electrode and a second electrode that wind in a first direction for a first distance, and in a second direction for a second distance; and a bracket that includes structures that hold the first electrode and the second electrode in place.
Example embodiment 11: The electrolyzer electrode assembly of example embodiment 10, wherein the at least first electrode and second electrode wind in the first direction and in the second direction for at least a second time.
Example embodiment 12: The electrolyzer electrode assembly of example embodiment 10 and 11 wherein the radius of the wind in the first direction is less than the radius of the wind in the second direction.
Example embodiment 13. The electrolyzer electrode assembly of example embodiment 10, 11, and 12, wherein the first electrode and the second electrode are configured to include a plurality of concentric parts.
Example embodiment 14: The electrolyzer electrode assembly of example embodiment 10, 11, 12, and 13, wherein the bracket includes four sections that include spaces for holding the first electrode and the second electrode in place.
Example embodiment 15: The electrolyzer electrode assembly of claims 10, 11, 12, 13, and 14, wherein the bracket includes a plurality of rows of spaces for holding the first electrode and the second electrode in place.
Example embodiment 16: A method, comprising: providing a container; providing electrode ports coupled to the container; and providing a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.
Example embodiment 17: The method of example embodiment 16, further including: providing a bracket inside the container extending in a first direction away from the electrode entrance ports.
Example embodiment 18: The method of example 17, wherein the plurality of electrodes are held in place by the bracket.
Example embodiment 19: The method of example 16, 17, and 18, further including providing a ported outlet pipe coupled to the container.
Example embodiment 20: The method of example embodiment 19, wherein the ported outlet pipe includes the electrode ports.
Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of the present disclosure.
The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Accordingly, new claims may be formulated during prosecution of the present application (or an application claiming priority thereto) to any such combination of features. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in the specific combinations enumerated in the appended claims.
The following examples pertain to further embodiments. The various features of the different embodiments may be variously combined with some features included and others excluded to suit a variety of different applications.

Claims

What is claimed is:

1. An electrolyzer, comprising:

a container;

electrode ports coupled to the container; and

a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.

2. The electrolyzer of claim 1, further including: a bracket inside the container extending in a first direction away from the electrode ports.

3. The electrolyzer of claim 2, wherein the plurality of electrodes are held in place by the bracket.

4. The electrolyzer of claim 1, further including a ported outlet pipe coupled to the container.

5. The electrolyzer of claim 4, wherein the ported outlet pipe includes the electrode ports.

6. The electrolyzer of claim 1, wherein the radius of the wind in the first direction is less than the radius of the wind in the second direction.

7. The electrolyzer of claim 4, wherein the ported outlet pipe includes a bracket securing component.

8. The electrolyzer of claim 4, wherein the ported outlet pipe includes gas ports.

9. The electrolyzer of claim 4, wherein the ported outlet pipe includes a pressure release valve.

10. An electrolyzer electrode assembly, comprising:

at least a first electrode and a second electrode that wind in a first direction for a first distance, and in a second direction for a second distance; and

a bracket that includes structures that hold the first electrode and the second electrode in place.

11. The electrolyzer electrode assembly of claim 10, wherein the at least first electrode and the second electrode wind in the first direction and in the second direction for at least a second time.

12. The electrolyzer electrode assembly of claim 10, wherein the radius of the wind in the first direction is less than the radius of the wind in the second direction.

13. The electrolyzer electrode assembly of claim 10, wherein the first electrode and the second electrode are configured to include a plurality of concentric parts of different radius.

14. The electrolyzer electrode assembly of claim 10, wherein the bracket includes a plurality of sections that include spaces for holding the first electrode and the second electrode in place.

15. The electrolyzer electrode assembly of claim 10, wherein the bracket includes a plurality of rows of spaces for holding the first electrode and the second electrode in place.

16. A method, comprising:

providing a container;

providing electrode ports coupled to the container; and

providing a plurality of electrodes that extend from outside of the container through the electrode ports into the container and wind in a first direction for a first distance away from the electrode ports, and in a second direction toward the electrode ports.

17. The method of claim 16, further including: providing a bracket inside the container extending in a first direction away from the electrode ports.

18. The method of claim 17, wherein the plurality of electrodes are held in place by the bracket.

19. The method of claim 16, further including providing a ported outlet pipe coupled to the container.

20. The method of claim 19, wherein the ported outlet pipe includes the electrode ports.